THE ARUP JOURNAL

SHABANI SPECIAL ISSUE 1981

 THEARUP
JOURNAL
Front c o v e r : Underground w o r k i n g s s h o t holes being prepared ( P h o t o : B o b D a v e y )
B a c k c o v e r : C o n i c a l tower. Great Z i m b a b w e
Design of a
new asbestos mill in
Shabani, Zimbabwe
Introduction
S h a b a n i and Mashaba M i n e s ( P r i v a t e ) Ltd.
have recently completed the construction
of one of the w o r l d ' s biggest and most
modern asbestos mills in S h a b a n i , Z i m b a b w e ,
at a cost in e x c e s s of Z $ 1 0 0 m . ( F i g . 1 ) .
The monthly milling capacity of the n e w mill
is designed to be 2 0 0 , 0 0 0 tonnes of ore.
Shabani has the largest reserves of asbestos
fibre in Southern Africa. T h e deposit occurs
near the base of a lenticular ultrabasic sill
14.5km long and 2.4 to 4 . 8 k m w i d e , w h i c h
intrudes early P r e - C a m b r i a n gneisses. T h e
quality is good and the length of fibre is up to
3 0 m m in places.
T h e design and construction w a s controlled
by African Associated M i n e s ( P r i v a t e ) Ltd.,
Secretaries and Consulting Engineers to
S h a b a n i and M a s h a b a M i n e s (Private) Ltd.
Ove Arup and Partners provided an 'arms
and legs' service to A A M by supplying the
engineering skills that w e r e lacking in their
o w n organization. In broad terms A A M
carried out the design of the plant and the
mechanical equipment w h i l e Arups handled
the civil, structural and electrical aspects.
Programming and cost control were handled
jointly. Fig. 2 s h o w s diagramatically the
breakdown of w o r k into the various disci-
plines. T h i s paper briefly describes A r u p s '
work, w h i c h w a s completed at a cost of
approximately Z $ 4 3 m .
The process
The extraction of asbestos fibre from ore is a
lengthy a n d complicated process w h i c h
varies between different ore bodies. At
S h a b a n i , the ore is mined at various levels
d o w n to a depth of about 5 7 0 m .
2 T h e mill has t w o basic s e c t i o n s ; the feed
Vol. 16 Shabani special issue 1981
Published by
O v e A r u p Partnership
13 Fitzroy Street. London W1 P 6 B Q
Editor: Peter Hoggett
Art Editor: Desmond Wyeth F S I A D
Assistant Editor: David Brown
system ( F i g s . 3 , 4 and 5 ) and the treatment
plant. In the feed system, the ore is taken
from the w e t ore stockpiles ( F i g . 6 ) and is
crushed, screened, dried and fed into the
dry ore stockpile. From these stockpiles,
the ore is carried on conveyor belts to the
top of the treatment plant. It then gravitates
d o w n through a series of screens w h e r e the
fibre is separated from the rock and is
carried in a current of air to c y c l o n e s , w h e r e
it is deposited. T h e rock residue is treated in
fibreizers and screened again to separate
out the shorter fibres.
After a s u c c e s s i o n of similar processes, the
rock, by n o w a fine s a n d , is sent to a discard
dump. The separated fibre in the c y c l o n e is
cleaned to remove dust and grit, graded by
length, and opened to the required degree.
It is then blended to specification and bagged
ready for shipment.
T h e process design for the removal of the
asbestos fibre from the ore is an art based on
years of experimentation and experience.
Testing of prototype items of plant w a s
carried out throughout the design period. T h e
final structural design and production of
reinforcing s c h e d u l e s goes from the f o u n -
dations upwards, i.e. in the opposite direction
to the mechanical design. A s the various
designs w e r e developed simultaneously, a
structural system w h i c h could accept c h a n g e s
w a s required. T h e electrical design developed
alongside the mechanical and had to be able
to accept additional loads as the process
w a s refined.
Historical development
A similar mill, at King Mine, roughly t w o
thirds the size of the one at S h a b a n i , w a s
built at M a s h a b a , 4 0 k m a w a y , 1 0 years
earlier by the s a m e group. The design of the
King Mine treatment plant w a s based on a
vertical f l o w of materials through the
reduction process rather than the horizontal
f l o w previously adopted by this group. T h i s
concept proved s u c c e s s f u l and w a s repeated
at S h a b a n i . It obviously radically c h a n g e s
the structural concept and g i v e s rise to a n e w
form of treatment plant.
Prior to the commencement of design of the
King Mill, it w a s assumed that the building
w o u l d f o l l o w tradition and have a steel frame
w i t h reinforced concrete infill floors. A r u p s
w e r e commissioned to carry out the structural
design. Together with A A M , they decided to
use a solid flat slab concrete solution. T h i s
decision w a s based mainly on e c o n o m i c c o n -
siderations and it has other advantages. All
necessary skills and materials for the c o n -
struction of concrete structures are available
throughout Z i m b a b w e , w h i l e the majority
of steelwork for large structures requires
the expenditure of foreign currency for supply
and erection. T h e comfort and safety of the
workers within the plant is of major c o n c e r n ,
and an all-concrete structure provides fewer
crevices for dust and is easier to w a s h d o w n .
Delays in supplies of structural steelwork
are a l w a y s a serious disadvantage.
A possible disadvantage of a concrete
solution is in reduced flexibility for c h a n g e
once the structure is complete. This problem
w a s s o l v e d , in effect, by overdesigning by
an agreed margin to allow for c h a n g e s . From
the experience gained on the M a s h a b a
Project as well as from other similar j o b s ,
the concrete solution w a s further developed
at S h a b a n i to provide not only the structural
frame, but also in places, a part of the plant.
In order to be s u c c e s s f u l , the total plant,
including the construction, operation and
maintenance, had to be c o n c e i v e d as a w h o l e .
Environmental conditions within the plant,
comfort and safety of staff, maintenance
costs, including those for d o w n time, and
availability of skilled labour, were among the
features considered during the design. T h e
text d r a w s attention to certain of these
aspects.
Civil design
T h e civil engineering w o r k s w h i c h w e r e
broken d o w n into a number of contracts
included upgrading existing services a n d
 lit: V:

Fig.1
General v i e w of completed project

Fig. 2
B r e a k d o w n of work into various disciplines

Fig.3
Feed system : dryer building
s h o w i n g top of vertical dryer

Fig.4
Feed system : w e t pick-up building
s h o w i n g Q - d e c k dryer

Fig. 5
Feed system : screening plant
typical floor

Fig.6
Site surfacing and feed system :
wet ore stockpile
 providing n e w facilities. T h i s work w a s
carried out in the period Au g u st 1 9 7 6 to
J u n e 1 9 8 0 at a total cost of around Z $ 4 m .
Of this, Z $ 2 m . w e r e part of the main project
w h i l e Z $ 2 m . w e r e for projects off-site.
Off-site housing
T h e decision to establish the n e w asbestos
mill at S h a b a n i gave rise to an immediate
requirement for additional housing on the
site. Traditionally the mine has provided
housing for all its w o r k e r s . T h e short-term
need w a s to provide housing to replace that
lost on the mill site and for the influx of
construction workers required to complete
the project, w i t h a longer term requirement
for the additional mine workers necessary to
cope w i t h the increased production. T h e
housing required w a s in three grades, w i t h
requirements of 6 0 high cost units, 2 0 0
medium cost units and 4 0 0 l o w cost units.
T h e l o w cost and some of the high cost units
w e r e located in an infill pattern in existing
t o w n s h i p s on the mine, w i t h the other units
in n e w t o w n s h i p areas.
O v e Arup and Partners carried out the
planning for the housing and the civil
engineering design for water and s e w e r a g e 7A 8T
reticulations, roads, stormwater drainage and Fig. 7
electrical reticulations. All housing units had Area of completed high cost housing
individual c o n n e c t i o n s to water supply,
s e w e r a g e reticulation and electricity, thereby
breaking a w a y from the tradition on the mine
for c o m m u n a l facilities for l o w - c o s t housing.
Street lighting w a s provided in all housing
areas. T h e services design maximized the
use of locally available material with asbestos
e5>
cement piping being used extensively for
water and s e w e r a g e reticulations and locally
available gravel for road construction. F i g . 7 Fig.8
s h o w s an area of completed high cost S e w a g e pumping station
housing.

D i v e r s i o n of s e r v i c e s
T h e site c h o s e n for the n e w mill w a s an area
previously used for low density housing and
included, on the eastern boundary, the
national road from S h a b a n i to B u c h w a . All
the houses in the area w e r e to be demolished
but certain services, serving areas outside
the limits of the mill site, ran through the area.
Before bulk earthworks could c o m m e n c e ,
all these through services had to be diverted
and the national road moved beyond the
confines of the site. T h e planning of the mill
complex w a s in its early stages at this time
and conservative estimates had to be made
of the likely extent of the mill site.
T h e diversion of the B u c h w a road comprised
a length of approximately 8 0 0 m over some
difficult terrain. T h e c r o s s - s e c t i o n of the road
w a s the Government standard for this c l a s s
of road of 7 m of surface on a 10m base
course. Geometric standards laid d o w n by
the Government for national roads w e r e
complied w i t h , in spite of the fact that at the
present, it is a gravel road on a very poor
alignment, approximately 2km from S h a b a n i .
T h e main pipe services crossing the mill site
consisted of a s e w a g e pumping
potable and industrial water supply mains
and a return s e w a g e effluent main. P l a n s
had already c o m m e n c e d for an upgrading
of all these services and the immediate need
w a s therefore a short-term temporary diver-
sion around the site. T h e four pipelines w e r e
laid adjacent to each other in a single trench
with minimal cover around the western and
northern boundaries of the site.
Water supply
The water supply to S h a b a n i c a m e from the
Lundi River. At the time of the start of the mill
project, w o r k w a s already under w a y on the
design and construction of a new dam on the
Ngezi River to supply S h a b a n i with water.
In v i e w of this, w e w e r e asked to investigate
the water reticulation on the mine, and to
report on it. T h e entire mine complex is
4 supplied with a dual reticulation supplying
both potable and industrial water. T h e
industrial water is recovered from the under-
ground w o r k i n g s and is used in the process
and for garden watering. All water used on
the mine is supplied free of charge to the
mine personnel, and the per capita c o n s u m p -
tions are therefore enormous. Our report
envisaged a rationalization of the main water
reticulation to cater for the projected increase
in population and the raising of living standards
of the lower paid workers. The philosophy of
bulk water storage on the mine w a s also
examined and reported on.
A s a result of this report w e w e r e c o m m i s - required, so that ultimately the system w o u l d
sioned to implement the first part of the
recommendations w h i c h consisted of as h o w s a typical pump station w i t h inlet w o r k s
1 2 , 0 0 0 m storage reservoir and 2.5km of
1
supply pipeline. T h e reservoir, of reinforced
concrete, w a s constructed on a hill over-
looking the n e w mill site and positioned to
a l l o w for the construction of t w o future
reservoirs of similar size, as the demand
required. The pipeline, w h i c h w a s 4 5 0 m m
diameter asbestos cement, supplied water to
the reservoir from the main pump station at
w h i c h the Ngezi water supply w a s received.
main,
Sewerage reticulation
Simultaneously with the appointment to construction of the treatment plant it w a s
investigate the overall water reticulation of
the mine, w e w e r e appointed to produce a
similar report for the overall s e w e r a g e
reticulation. T h e terrain of S h a b a n i is made
up of numerous small hills with housing
areas generally located in the valleys between.
Very limited use can therefore be made of
gravity s e w e r a g e . A complex of s e w e r a g e mill site.
pumping stations existed over the mine with
several of these obviously overloaded. Our
report recommended the rationalization and
upgrading of the pumped s e w e r a g e system
as a phased development. T h e upgrading and
re-siting of one of the pump stations serving
the l o w - c o s t housing areas had already been
required as a result of the extension of the l o w -
cost housing, and this, together with a
secondary pump station pumping into it and a
delivery main to the treatment w o r k s , had
been included in our brief for the housing
services. The next phase for w h i c h w e w e r e
appointed w a s the design of the necessary
upgrading of the system serving the southern
part of the mine. This consisted of four pump
stations and approximately 4 k m of pumping
main, and 4 k m of gravity s e w e r s .
The pumping stations w e r e all designed as
identical underground structures w i t h s u b -
mersible pumps. A l l o w a n c e w a s made in the
design for increasing the number of p u m p s
and duplicating the delivery mains w h e n
cope with the f l o w s anticipated in 1 9 9 5 . Fig. 8
for grit removal.
T h e mill s i t e
T h e civil engineering on the mill site w a s
carried out in four stages. T h e first of these
w a s the bulk earthworks. Prior to c o n s t r u c -
tion, the site consisted of fairly rough, tree
covered terrain with a m a x i m u m fall across it
of the order of 1 2m and a natural water course
through the centre. B e c a u s e the planning of
the feed system w o u l d not be completed
until some time after the c o m m e n c e m e n t of
necessary to provide an earthwork solution
that allowed flexibility in the planning. It w a s
therefore decided to provide a cut and fill
platform over the entire site. T h i s platform w a s
generally graded to falls of 1 :100 to permit
drainage of the surface. T h e water course w a s
diverted around the southern extremity of the
A s the planning of the mill complex became
more finalized it w a s possible to design the
s e c o n d stage of the civil w o r k s . T h i s consisted
of the s e w e r a g e reticulation for the site, and
roads and stormwater drainage over the
northern portion.
T h e third stage took the stormwater drainage
a step further and provided temporary drainage
in the areas not finalized. T h i s w a s carried out
priorto the 1 9 7 8 rainy s e a s o n .

The fourth stage w a s the completion of the
stormwater drainage, finalization of the site
levelling, the roads, the surfacing of the site,
the completion of the s e w e r a g e reticulation
and the intersection of the main a c c e s s road
to the site w i t h the Shabani to B u c h w a road.
The stormwater drainage consists principally
of open concrete lined drains ( F i g . 9 ) , piped
or culverted. Underground stormwater drain-
age w a s avoided wherever possible, as the
milling process produces large quantities of
fibrous dust w h i c h , during S h a b a n i ' s long
dry season, c o u l d easily block invisible storm-
water drainage routes. T w o main drains ran
through the site, one at the southern extremity
carrying the water from the diverted water
course as w e l l as water from the southern
portion of the site. T h e other main drain
through the centre of the site picked up a
small catchment outside the site and also
drained the majority of the site ( F i g . 1 0 ) . A t t h e
western end of the site, w h e r e the central
drain discharged, the bulk earthworks contract
had raised the finished level some 8 m above
natural ground level. T h i s required a s p i l l w a y
structure to take peak flow of approximately
1 1 m / s e c . prior to passing it under the main
3
mine hall road ( F i g . 1 1 ) .
The main a c c e s s road into the site carries the
finished product from the mill to the rail head
for d e s p a t c h . T h i s w a s the only formal road
on the site, and w a s a 7 m surfaced road on a
10m base. T h e client's requirements for the
remainder of the site w e r e that v e h i c l e s should
be able to drive a n y w h e r e w i t h o u t being
impeded by stormwater drainage or other
surfaces. T h i s required that secondary drains
on the site s h o u l d be s h a l l o w dish' drains,
permitting v e h i c l e s to cross. T h e entire 2 5 h a
site w a s therefore topped w i t h a compacted
gravel layer sealed w i t h a single seal surface
dressing. Within this, identifiable heavy
traffic routes w e r e demarcated, with double
seal surfacing in these areas. Figs. 6 and 12
s h o w some of the surfaced area with d i s h '
drains.
Fig.9
S e c o n d a r y drain to
south of treatment
plant building
Fig.10
M a i n drain
through mill site
Fig.11
S p i l l w a y from
mill site
Fig.12
Site surfacing
Structural design
T h e total civil and structural engineering
w o r k s on the mill site were completed for a
cost of Z $ 2 7 . 3 m . T h e treatment plant repre-
sents 5 8 % of the civil contract, the remaining
buildings 3 4 % , w h i l e the bulk e a r t h w o r k s ,
diversion of existing services, site roads,
stormwater drainage, etc., make up the
remaining 8%.
Building work on the treatment plant building
c o m m e n c e d in October 1 9 7 7 and w a s c o m -
pleted in December 1 9 7 9 , w h i l e the feed
system w a s completed in May 1 9 8 0 . T h e total
civil/structural work force peaked at 2 , 6 5 0
in February 1 9 7 9 .
T r e a t m e n t plant
T h e main structural design effort w a s directed
t o w a r d the treatment plant. T h i s building
rises 1 0 0 . 6 m above the ground, and has a
double basement to a depth of 5.5m. T h e
total floor area is 1 3 8 , 0 0 0 m . T h e first main
2
nine floors are 1 0 0 . 5 x 7 6 . 5 m , stepped back
at the ninth level up to the 16th floor. T h e
upper main floors are 1 0 0 . 5 33.0m. Fig. 13
s h o w s a section through the treatment plant.
A typical main floor, w h i c h c o n s i s t s of four
f l o w lines, a service bay and a perimeter
c o n v e y o r corridor, is s h o w n in F i g . 17.
Most of the plant is carried on the main floors.
T h e column grid w a s selected to impose
minimum restraints on the plant layout and
at the same time, together w i t h the box
c o l u m n s , provide a linear surface on w h i c h
to attach crane rails, conveyor gantries and
so on. C o l u m n sizes w e r e constant for the
entire building. Major floor openings, i.e. larger
than 1.2m square, w e r e decided before the
slab w a s cast, w h i l e many minor openings
w e r e added after the reinforcing had been
designed and detailed. Where possible, these
were added before the concrete w a s cast, but
in some cases w e r e punched through the
coffer topping afterwards. Approximately
8 0 % of the openings, other than major
openings c o m m o n to all typical main floors.
fell within the coffer topping and could
therefore be ignored in the d e s i g n .
In each flow line there are three service ducts
( b o x c o l u m n s ) w h i c h act as air plenums
connecting the fan c h a m b e r s to the various
main floors. T h e box c o l u m n s also act a s
vertical shafts to enclose electrical cables,
stairs and other services. O p e n i n g s are pro-
vided in the sides to a l l o w a c c e s s w h e r e
required. T h e main floor to floor height is 6 m .
B e t w e e n the first and s e c o n d floors and for
12 floors thereafter, hung floors are used for
working platforms to the machinery on the
main floors. All floors, including the hung
floors, will be w a s h e d d o w n w h i l e the plant
is in operation and therefore openings are
provided with upstand surrounds except the
w a s h d o w n outlets. A s c a n be seen in F i g . 1 3 ,
the hung floors cover only portions of the
complete floor area. M a n y of the items of plant
on one main floor are c o n n e c t e d to the plant
on the floor above or below by s c r e w c o n v e y -
ors or c h u t e s . T h e openings required in the
hung floors are more n u m e r o u s and often
larger than in the main floors and w o u l d have
made s p a n n i n g between the main vertical
supports difficult w i t h a reasonable depth of
slab. For this reason additional supports from
the main floors w e r e a d d e d . Hanging rather
than propping the intermediate floors w a s
decided upon to allow m a x i m u m w o r k i n g
space above and around the plant on the
main floors ( F i g s . 1 4 , 1 5 a n d 1 6 ) .
In order to maintain the rhythm of the c o n -
struction programme simple standard elements
were used to a m a x i m u m , although in some
c a s e s this w a s extravagant in terms of
materials. W h e r e it w a s no longer possible to
use or justify the use of standard elements,
conventional building t e c h n i q u e s w e r e u s e d .
T h e main non-typical section of the treatment
plant is the dust filter area, situated at the top
of the l o w portion. T h i s area h o u s e s 10 fans,
t w o of w h i c h are on standby. T h e remaining
eight provide 5 7 , 0 0 0 m of air a minute for the
3
plant. T h e air c h a m b e r s operate at a negative 5
Fig.13
S e c t i o n through treatment plant

Fig.14
Treatment p l a n t : seventh
floor w i t h equipment installed

Fig.15
Treatment p l a n t : typical main
a n d intermediate hung floor

3
w i t h equipment installed

Fig.16
Treatment p l a n t : main floor
w i t h c y c l o n e s projecting through
h u n g floor as above
13A 14T 15T
pressure of 3 7 5 m m of water gauge. T o save 2 . 8 5 m square panels with soft board joints
foreign currency the w a l l s of the chambers are between panels
cast in situ concrete and the dust hoppers are ( 3 ) 1 0 0 0 gauge polythene sheeting
precast concrete. T h e construction of the double welt folds
filter area and the high portion of the treat-
Main floors
T h e s e are of 1.5m square coffer construction
with w i t h an overall depth of 0.5m ( F i g . 1 8 ) . T h e y
are designed for a superimposed load of
1 5 . 6 k N / m ( m a i n floor live load 6 . 0 k N / m ,
2 2

( 4 ) 2 m m thick waterproofing membrane of

ment plant building proceeded simultaneously. hung floor live load + dead load 9 . 6 k N / m ) . 2

butyl rubber sheeting with z i g - z a g edges

No expansion joints are provided in the treat-
ment plant building except at roof levels, and
then not for those areas over the filter
chambers. T h e roofs over the filter chambers
are insulated to reduce thermal movement.
Additional reinforcement w a s added to cater
for thermal and shrinkage strains.
The main reason for no joints w a s to avoid
having to cater for movements in s u c h
mechanical equipment as s c r e w c o n v e y o r s ,
chutes, crane rails and so on.
Waterproofing of the filter c h a m b e r s w a s
particularly critical, as any water or air leakage
w o u l d interfere with the process. Working
d o w n w a r d s from the top the waterproofing
medium w a s built as follows :
( 1 ) 4 5 0 x 4 5 0 X 4 0 m m thick precast concrete
slabs with 2 5 m m open joints between slabs
(2) 75mm sand/concrete cover
glued together on site
( 5 ) 2 5 m m thick polyurethane
bonded to concrete
(6) Surface of concrete or screed.
In less critical areas waterproofing consists of
t w o layers of mastic asphalt layed on Kraft
bituminous paper and covered w i t h flat
asbestos/cement roofing tiles.
A minimum of 1 in 8 0 falls w a s achieved
either by tilting the slab, or by laying a screed
to fall.
T h e six standard building elements used for
the treatment plant building are itemized
below. These w e r e developed in close
collaboration with the civil contractor w h o s e
practical experience w a s i n v a l u a b l e . M o c k - u p s
of all the standard elements were made before
the construction of the treatment
slab in commenced.
T h e y w e r e also designed to have props
removed after s e v e n d a y s and to carry a
insulation
subsequent floor after 14 days. T h e design
a l l o w s for additional openings up to 1.2m
square to be added any time through the
coffer topping. Cable routes were provided
within the coffer depth in specified locations
both to protect the c a b l e s and to minimize
space requirements. Additional shear r e i n -
forcement w a s provided locally in the coffer
ribs. ( F i g . 1 9 ) .
Hung floors
These are 2 0 0 m m solid slabs. Support points
for the hung slabs w e r e confined to the inter-
section of ribs in the main slab, but the c h o i c e
of intersections depended on the plant layout.
Often they were irregularly placed, not at the
optimum structural s p a c i n g . T h e s e slabs
plant were designed using yield line technique.
(Figs.20and21).

Fig.17
F l o w line F l o w line i Service B a y
F l o w line F l o w line
'4 T y p i c a l main floor plan
of the treatment plant

Fig.18
12 Treatment p l a n t : B line w a l l
(south side of building)

y 3<H px^ - i 83G

( P h o t o : R o b a l S t u d i o s ( P v t . ) Ltd.)

Fig.19
*3 i 3 -JP4= " 2 1
Coffer rib w i t h additional
is a a la a 14-t 2
shear reinforcement
T7 P 5 15 F i g . 20
8 I 6 Treatment plant building : fourth and
7 fourth intermediate hung f l o o r s s h o w i n g
' C line c o l u m n and B - C box c o l u m n s
( P h o t o : R o b a l Studios ( P v t . ) Ltd.)

F i g . 21
16
Treatment plant building : sixth floor
a n d sixth intermediate floor s h o w i n g
17 openings for c y c l o n e s in intermediate floor
I I
( P h o t o : Robal S t u d i o s ( P v t . ) Ltd.)
I I
I
19
I I

Key
Plant openings 1. Bucket elevators 1 1 . S u p p l y air plenum
typical to 2. Electrical cable duct 12. Crane w a l l to w o r k s h o p
all main 3. S u p p l y air plenum 1 3. Material hoist
floors 4. Return air plenum 14. Passenger elevator
Plant openings 5. Stairs and main elevators 1 5 . Main stairs
peculiar to a 6. Return air plenum 16. Material hoist
particular 7. S u p p l y air plenum 17. Small materials hoist
floor (71 on 8. Electrical cable duct 18. T o w e r crane openings
example s h o w n ) 9. Electrical cable duct (temporary)
Conveyor 10. Return air plenum 1 9. Spiral stairs
Corridor

17A 18T 19T 20 A 21T

elllJ
* 7
 H a n g e r t o p section
cast into concrete

a) Stepl

Hangertop section
remains after props
b) Step 2 have been removed

Fig. 22
Perspective v i e w of hanger design

Hangers
T h e design of the hangers removed them as a
restraint on the construction critical path as
they did not interfere w i t h the propping of a
slab or of the subsequent slab. T h e hangers
are e n c a s e d in concrete for protection.
Fig. 2 2 s h o w s the hanger design and Figs.
2 3 a , b a n d c s h o w the s e q u e n c e of c o n -
structing the main and hung floors.

Box c o l u m n s
T h e s e have 2 5 0 m m w a l l s . Structurally their
function is to provide vertical supports and
lateral stability. T h e internal w a l l s and floors
were cast after the outside shell.
Columns Hanger lower
One standard size of 0 . 7 5 X 1.5m w a s used section bolted
for all c o l u m n s . Their bending stiffness relative into place
to the slab permitted a reduction in the overall
design moment of the slabs.
Precast cladding units (Fig. 24)
T h e total area of cladding is 3 0 , 0 6 2 m . 2

Precast concrete, structural steel supporting

a s b e s t o s / c e m e n t sheets a n d glass reinforced
cement panels were among the alternatives c)
considered. T h e cladding needed to be sturdy
and durable as replacement or repairs w o u l d
be costly and difficult. T h e precast concrete
solution turned out to be the cheapest and F i g . 23
the one w h i c h best suited the client's require- S e q u e n c e of
ments. T h e typical panels are 6.5 X 1.5m in constructing the
size w i t h a mass of 1 4 8 0 k g ( F i g . 2 5 ) . T w o main and h u n g
w i n d o w s per panel are provided to give a floors
human scale to the units.
T h e vertical joints between panels are o p e n -
drained w i t h a baffle strip and an air seal. T h e
setback in the building between the ground
and the first floor simplified the waterproofing
detail at the ground floor and provided a
covered w a l k w a y around the building.
B r i c k w o r k w a s used between the ground and
the underside of the first floor. A precast F i g . 24
solution used up to the underside of the first Precast cladding units
floor on King Mill treatment plant project (Photo:
proved costly, because the numerous o p e n - Ove Arup & Partners
ings at this level resulted in a number of Zimbabwe)
8 non-typical panels.
 Construction
T h e use of standard elements made possible
a fast rate of construction on the site. A
500mm minimum programme of 19 d a y s per floor w a s
achieved, w i t h an average of 26 d a y s per
floor. T h e m a x i m u m concrete pours w e r e in
e x c e s s of 4 0 0 m per day ( F i g . 2 6 ) .
3

Four tower cranes, each capable of lifting

2 , 5 0 0 k g at full reach were used on the
treatment plant. Concrete w a s supplied from
t w o mixers on the east and w e s t of the
building. Their m a x i m u m delivery rate w a s
1 5 m / h o u r e a c h . Concrete w a s moved into
3

position either in s k i p s or by pumping. T h e

m a x i m u m output of the pump w a s rated at
5 0 m / h o u r , but this w a s never achieved as it
3

exceeded the rate of the mixer. Pumped

concrete w a s used for the entire height of the
building. Concrete slumps were 3 5 - 4 5 m m
and 8 5 - 1 0 0 m m for conventionally placed and
pumped concrete respectively. In the solid
c o l u m n s only conventionally placed concrete
w a s used. E l s e w h e r e both types of concrete
were used interchangeably.
5.5m T h e main slabs w e r e formed w i t h fibre glass
moulds and steel pans supported on tubular
steel props, at 1.5m centres each w a y ( F i g .
2 7 ) . T h e support system a l l o w e d for the
removal of the coffer mould, leaving props
in place at the intersection of the ribs. For
typical areas reinforcing w a s made up into
cages before being lifted onto the deck, and
then joined together using splice bars. T h e
amount of steel fixing done in place w a s kept
to a practical minimum.

T h e 2 0 0 m m hung slabs were formed using

steel pans, carried on beams, supported by
steel props s p a c e d on a 1.5m x 3 . 0 m grid.

F i g . 25
T y p i c a l precast panel

F i g . 26
General v i e w of treatment plant
building, packed fibre store
and mechanical equipment store
( P h o t o : Robal Studios ( P v t . ) Ltd.)

**K
l >

)
i

I3E

F i g . 27
Treatment p l a n t : s e c o n d floor coffers in position and steel being fixed
(Photo : Robal Studios ( P v t . ) Ltd.)
Again it w a s impossible to remove the pans
w h i l e leaving the props in place. Welded wire
mesh w a s used for top and bottom reinforcing
over the entire slab. C u t - o u t s for openings
were made on site and additional reinforcing
added at supports and around openings.
T h e hollow c o l u m n s and all other w a l l s were
formed w i t h gang forms. Where possible,
prefabricated reinforcing panels w e r e used.
T h e w a l l s were poured continuously over the
5.5m height in approximately 2.0m lifts. T h e
internal w a l l s and slabs were cast afterwards.
R e v i e w i n g the design and construction of the
treatment plant in retrospect, one structural
element that could obviously have been better
designed w a s the box c o l u m n s , especially as
they were on the critical path. Unfortunately
the mechanical designers could not maintain
the slab module in the vertical direction and
openings in the w a l l s occurred almost
a n y w h e r e . T h i s complicated the design and
the detailing, thus c a u s i n g delays in the
construction. Had this restraint been fully
appreciated at the outset it may have been
possible to provide structural c o l u m n s in the
corners with large non-structural infill panels
w h i c h could have been added later.
Solid c o l u m n s were cast using steel box
shutters. T h e reinforcing c a g e s were pre-
fabricated.
T h e precast concrete cladding units were cast
in a yard adjacent to the site. They were lifted
onto the buildings at night using the tower
cranes.
A qualified surveyor w a s attached to the
resident engineer's team to monitor the
a c c u r a c y of the building. External reference
beacons w e r e used to establish internal
control b e a c o n s at ground level. T h e s e four
corner points w e r e then transferred u p w a r d s
w i t h a precision optical plumb to provide a
replica of control for construction w o r k on
each floor.
Specific construction lines were then e s t a b -
lished at e a c h construction level by theodolite
observations and offset measurements from
this control grid. From these, reinforcing and
shuttering w e r e erected and c h e c k e d before
concrete w a s poured. Ideally these secondary
construction lines should have been set out
and adjusted proportionately between the
main framework before construction w o r k
c o m m e n c e d . H o w e v e r , as it w a s not practical
to complete one floor before proceeding to
the next, setting out work had to be carried
out piecemeal, usually from one corner of the
building.
The points and lines established in this manner
on upper floors were c h e c k e d from time to
time by direct observation and measurement
to external b e a c o n s . B y and large the monitor-
ing of construction w o r k w a s carried out
using a combination of triangulation, precise
traversing a n d levelling from outside control
beacons or n e w stations established in
convenient positions. A system w a s devised
to continually c h e c k a l l - 1 6 5 c o l u m n s and
points of structural significance and process
the results by computer. A program w a s
developed to calculate the grid co-ordinates
of each corner of all the c o l u m n s , top and
bottom, on e a c h floor from a series of
adjusted traverses along each line of measure-
ments, north/south and e a s t / w e s t , closed on
the outside main grid control lines. T h i s data
w a s used to determine the positions of each
c o l u m n at e a c h floor level in turn, relative to
adjoining c o l u m n s in a horizontal plane and
to the same c o l u m n at a level immediately
above and below the particular level c o n -
cerned.
A survey w a s carried out on the effects of
c h a n g e s of temperature on the structure, both
during construction and to the completed
building. T h e results of this survey w e r e
n e g a t i v e ; if there w a s a temperature effect
it could not have exceeded the k n o w n
a c c u r a c y of the survey work of 4 m m
standard deviation.

F i g . 28
Histogram s h o w i n g difference between surveyed and design positions of the centre of gravity of c o l u m n s

120

110

100

90

80

s 7

cr
60
LL

50

40

30

20

10

0 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40

Differences between surveyed and design positions of the centre of gravity of c o l u m n s ( m m )

From the results obtained s h o w n in F i g . 28
for the difference between surveyed and
design positions of the centres of gravity of
the c o l u m n s , it c a n be seen that 1.6% of the
results are greater than 2 5 m m and 5 % are
greater than 2 0 m m . T h e results for the
difference between surveyed and design
positions of c o l u m n corners w e r e similar
with 1.7% of the results greater than 2 5 m m
and 4 . 7 % greater than 2 0 m m . T h e allowable
tolerance w a s 2 5 m m . T h e allowable tolerance
for the difference between the position of
column corners at the top and bottom of the
same column w a s 20 mm. 5 % of the results
were outside tolerance, 2 % were greater than
2 5 m m . T h e allowable tolerance for the
difference in position of c o l u m n corners
directly above and below a slab w a s 3 0 m m .
(3) Pit sand The following s y s t e m s were considered for
T w o sources of pit s a n d were used. T h e s e the fundamental control of the p l a n t :
were 2km from the site on the S h a b i River and (a) Computer based equipment.
2 5 k m from site on the Nyaratedzi River. (i) Programmable logic
A n on-site concrete team w a s established to controllers (PLC)
control the design and placing of the concrete. (ii) Micro processing units (MPU)
All aggregates complied w i t h the requirements ( b ) Solid state logic (SSL)
of the Central African Standard CASA34:
( c ) E l e c t r o - m e c h a n i c a l relays
1969. logics (EMRL)
Reinforcing bars available on the project Investigations revealed that the local ( Z i m -
consisted o f : b a b w e ) suppliers had neither the expertise
( 7 ) Square twisted high yield 3 0 , 2 5 , 2 0 , 16, nor facilities to provide this type of equipment
12 and 1 0 m m w i t h a characteristic strength on the scale necessary for the requirements of
fy=410N/mm 2
this project. Enquiries w e r e , therefore, directed
at the more prominent external suppliers. T h e
( 2 ) Hot rolled round mild steel 3 0 , 2 5 , 2 0 , 1 6 ,
analysis of these enquiries w a s then used to
1 2 . 1 0 , 8, 5.5mm with a characteristic strength
firm up on a satisfactory solution to the
fy=250N/mm 2

1.5% of results were greater than 3 0 m m and control problem and to open negotiation with
M a x i m u m bar length 1 2 m .
4 . 0 % of results were greater than 2 5 m m . T h e prospective suppliers,
above percentages were obtained using (3) Pre-stressing wire. T h e only size available (a) C o m p u t e r - b a s e d e q u i p m e n t
between 1,000 and 2 , 0 0 0 results and it is felt locally w a s 4 m m diameter strand w i t h a (/') Programmable logic controllers
that this gives a reasonably accurate result characteristic strength fy 1700N/mm . 2

T h i s class of equipment is cost-effective only

for the entire building. It is interesting to note Steel sections available locally consisted of w h e r e a high degree of logic in terms of input
that the a c c u r a c y of positioning c o l u m n s the following maximum sizes : related to output is necessary. From prelimin-
appeared to increase up the building with ary enquiries it w a s evident that the cost of
(7) 152 76 1 8 k g / m c h a n n e l s
a considerable increase between the third this type of equipment w a s in order of 2 0 0 %
and fifth floors, w h i c h coincided w i t h the (2) 230 25 4 5 k g / m flats more than that of the other alternatives. For
arrival on site of a full-time surveyor. {3) 100 100 1 7 . 8 k g / m angles this reason P L C d e v i c e s were given little
T h e actual position of the centre of gravity (4) 65 140 1 4 . 3 k g / m I beams. consideration.
for the vertical structure w a s determined at (//') Micro-processing units
Larger sizes were available but required the T h i s equipment proved to be slightly more
each floor. T h e largest distance from its design expenditure of foreign currency.
position w a s 9.9mm at the top of the s e c o n d expensive that the remaining alternatives but
floor. Labour w a s available in the area, but in most w a s not disregarded for this reason. Personnel
c a s e s w i t h no previous experience. During the with adequate technical expertise are at a
The geometry of a building s u c h as the site levelling and basement excavation phases premium in Z i m b a b w e . Recruitment of the
S h a b a n i Mill is important from t w o points of the project, a training school w a s estab- requisite calibre of staff a l w a y s presents a
of v i e w . Firstly from the structural point, lished on the site. G a n g s were trained on each problem. Another consideration w e i g h i n g the
w h e r e eccentricities c a n c a u s e significant specific standard building element by the decision in favour of the simpler s y s t e m s w a s
secondary stresses and, secondly, for pieces civil contractors. Construction techniques the high obsolescence rate of computer
of equipment s u c h as conveyors, lifts, etc., devised by the civil contractor's senior site equipment and its associated spares.
it is important that the structure does not staff enabled a high standard of construction
move out of plumb by more than the specified to be achieved w i t h the minimum use of
tolerance. skilled labour. T h e majority of their manage-
Civil engineering building c o n t r a c t ment and supervisory staff had to be imported
especially for this project.
T h e civil engineering contract for all buildings
in the mill w a s negotiated w i t h Grinaker Electrical design --
( A f r i c a ) ( P r i v a t e ) Ltd. Briefly, the contract
T h e following statistics give the scope of the
w a s handled as f o l l o w s :
electrical installation w h i c h w a s completed
During the preliminary design phase of the for a cost of Z$14 m., between the period
treatment plant, a bill of quantities based on J a n u a r y 1 977 and J u n e 1 9 8 1 .
provisional quantities measured from sketches
w a s prepared. Using these quantities and their Number of drives 4 , 0 0 0 plus
make up, rates were agreed by A r u p s and
Grinaker. A s final d r a w i n g s became available Installed transformer
at each level, they were measured and the capacity 42 MVA
agreed rates were applied to these quantities.
Reactive power 16 M V A V
In a similar w a y , separate bills w e r e prepared F i g . 29
from sketch plans for all buildings in the feed Service voltages 11,000/3300/ Typical cable racking,
systems, and then remeasured from final 550/400/230 below main floor coffered slab
d r a w i n g s . T h e treatment plant rates w e r e used
throughout, except w h e r e a n e w skill w a s Light fittings 12,000 F i g . 30
involved in w h i c h case a new rate w a s agreed. Cable access to s u b - b a s e m e n t ( b e l o w M C C s )
Total length cable 7 0 0 km
T h e cost plan w h i c h w a s prepared before
( F i g s . 2 9 and 3 0 )
construction commenced was updated
monthly as information firmed up. T h e s e costs Equivalent 1 0 , 0 0 0 km
were fed to the client w h o kept an overall cost single core cable
plan for the project. Escalation w a s based on
actual c h a n g e s to the make up of the rates Number of control 500,000
and w a s applied as it occurred. connections

Local material and labour Electrical staff 26 Design

T h e availability of local materials and skills (at peak) office, 4 Site
w e r e significant factors in the choice of the
Contractor's staff 80
structural concrete solutions for the different
(at peak)
buildings w h i c h make up the mill. Concrete
aggregate used on the project consisted o f :
Control system selection
(1) Coarse aggregate
It w a s necessary for the efficient operation,
A medium grained granite of reasonably
the utilization of labour and effective m a n a g e -
satisfactory quality obtained from Siboza I \
ment, that the large number of drives present
Quarry approximately 1 0 k m from site. I n c o n -
in this plant were centrally controlled, super-
sistent gradings and poor shape of this
vised and monitored. T h e high cost implica-
aggregate required close on-site attention.
tions resulting from d o w n time of the plant
( 2 ) Fine aggregate make it essential that any control applied is as
River sand w o n from the S h a b i River approxi- effective and simple as possible, whilst
simultaneously offering the m a x i m u m in \
mately 1 0 k m from the site. T h e fineness
modulus varied from 2.3 to 3.6 w h i c h again terms of fault diagnostic aids and fast \
required strict on-site monitoring. component replacement type. \\%\ \
(b) S o l i d s t a t e s y s t e m s
Solid state s w i t c h i n g c a n be considered
statistically superior to the electro-mechanical
relay with its attendant moving parts. H o w -
ever, the disadvantage with this system is the
l o w susceptibility to line-borne noise. Unfor-
tunately, disturbances of this nature cannot be
analyzed at the design stage.
Light current technicians necessary for the
maintenance of solid state systems have
generally progressed to higher employment
status and are not particularly interested in
maintenance positions. T h e residue of staff
available for maintenance is usually an
electrician w h o eludes or offers resistance to
black box techniques.
(c) E l e c t r o - m e c h a n i c a l r e l a y l o g i c
of the data logger is s u c h that no influence on
control is exercised. Malfunction of this
system does not therefore result in plant
stoppages.
D e s c r i p t i o n of c o n t r o l s y s t e m ( F i g s . 31
and 3 2 )
To meet the criteria of the provision of fault
diagnosis aids along with a quick component
replacement time, special c a r d s were designed.
Each motor control circuit w a s then allocated
a standard drive card. T h e s e cards w e r e
manufactured from printed circuit bases
before being loaded w i t h the necessary
relays and light emitting diodes ( L E D ) to
provide both control and fault diagnostic
functions ( F i g . 3 3 ) .
Supplementary cards ( a u x i l i a r y ) w e r e e m -
grammes are carried out at the interlock
matrix. ( F i g s . 34 and 3 5 ) .
Both the inputs and outputs of the drive and
auxiliary cards are represented at the inter-
lock matrix in the form of sockets. Flying
leads with corresponding plugs are then
employed to patch up the desired sequences.
A mimic display w a s provided to indicate
the process flow and drive status, the status
being confirmed by a multi-state indicating
lamp. T h e lamp indicates the following
conditions:
Red-field isolator o p e n / s t o p button operated
Amber (flashing) - alarm condition
Green - drive running
Blue - item e x c l u d e d from operation.

T h i s equipment without doubt offers the
greatest degree of operational stability. It is to
a large extent insensitive to disturbances that
generally create havoc on the more sophistic-
ated systems. No special k n o w l e d g e is
required for application. Further advantages
are realised from the basic simplicity of this
system. Maintenance staff usually possess a
rudimentary understanding of these s y s t e m s
and are therefore reasonably confident of their
ability to analyze, and subsequently rectify, in
an expedient manner, 9 9 % of most faults that
occur.
With an assessed m a x i m u m of six operations
per hour per relay a n d a quotient of 1 0 6
number of operations, the probable reliability
term of this class of equipment w o u l d be in
ployed to provide s u c h functions as timing
interludes and contact amplification.
The relays and components fitted to the above
mentioned cards were selected for 4 8 volt
D C , this being the highest available operating
voltage for miniature framed relays.
T h e drive control and auxiliary cards w e r e
accommodated in card files w h i c h were then
rack-mounted.
Integral to these relay racks are marshalling
and interlocking matrices w h i c h allow c o n -
nection of field inputs to the drive cards and
the subsequent s e q u e n c i n g / i n t e r ' o c k i n g pro-
F i g . 31
Typical hook-up
T h e mimic lights are driven from the respec-
tive drive cards, the signals being c o n v e y e d
via 50 core cables. The digital signals driving
the mimic display w e r e also employed as
status inputs to the event-recording data
logger. A g a i n 5 0 core cables were utilized
to transmit this information from the mimic
to the data logger ( F i g . 3 6 ) .
Control cabling
T h e extremely high density of incoming and
outgoing information to and from the relay
racks, mimics and field control stations made
it necessary to develop a special s c h e m e .
Local control station

1
e x c e s s of 2 0 years. diagram

i
Conclusion F i g . 32
On the basis of the foregoing considerations, Illustration of
the c i r c u m s t a n c e s particular to the project, Power Motor control centre
typical drive Marshalling box
reference and liaison w i t h other end users, it interlock
w a s our opinion that the electro-mechanical
relay logic w o u l d best fulfill the requirements F i g . 33
of this project. T y p i c a l drive card
It w a s decided that, in addition to the mimic Control Control desk
display, a data logging system should be logic panel
provided to record faults and the time at w h i c h
these faults occurred. It w a s therefore
necessary to perform this function w i t h a
( 1 5 , 0 0 0 lamps) Microprocessor-
computer-based microprocessor unit ( M P U ) .
mimic display based data logger
It may be argued therefore that the use of the
M P U for data logging purposes lent viability
Process information Monitors plant status
to the economical use of a computer-based
and drive status logs in real time
control system. H o w e v e r , feasibility studies
stoppages and
indicated that the cost savings w e r e insig-
identifies cause
nificant. Furthermore, the mode of operation

Field connections
for marshalling matrix

Drive Outputto M C C
card Output to interlocking matrix o Green L E D - Overload healthy
Input from interlocking matrix o Green L E D - C o n t a c t o r closed
Coil Drive card points represented o Red - I n t e r l o c k failed
N / O contacts on interlocking matrix
N / O contacts o Red - Stop button activated
Timer and auxiliary
N / O contacts
relays identical o Red - Alarm relay activated
+ ve j _
Start
button
02
]Drive1
]Drive2
]Drive3

Resistors

Relay Relay

Start Card end

D1 D2 D3 button
connectors
rive 1
Capacitors
Relay Relay

A
O

T1
Drive 2 ,
Time
interval Drive 3

W h e n it is considered that the average drive
has 11 incoming/outgoing c o n n e c t i o n s with
approximately 3,600 drives, the number of
terminating points at the relay racks are
therefore in the order of 4 0 , 0 0 0 . T o terminate
this amount by conventional terminals, each
3 m m thick, w o u l d have meant that the total
termination area w o u l d have been prohibitive.
For this reason high density aircraft type
plugs and s o c k e t s w e r e employed for these
37T
I for future g r o w t h . On this basis it w a s therefore
connections. Each p l u g / s o c k e t arrangement
a c c o m m o d a t e s 5 0 c o n n e c t i o n s in an area
approximately 25 6 0 m m . T h e total area
required w a s therefore approximately 1 , 2 m . 2
A further advantage gained from the use of
these connection arrangements w a s the
greatly reduced termination time, i.e. if 1 0
minutes are a l l o w e d per connection for
conventional s c r e w type terminals, 4 0 , 0 0 0
terminals w o u l d require 6,666 hours.
--''-I-Si
F i g . 34
Front v i e w of relay rack s h o w i n g
interlock matrix (note roof-mounted
s m o k e detectors)
F i g . 35
Rear v i e w of relay rack
s h o w i n g marshalling matrix
F i g . 36
Control room s h o w i n g
mimic panel and control desk
F i g . 37
Motor control centres (1 line)
T h e 5 0 core plugs each required a p p r o x i -
mately 15 minutes to terminate results in a
revised time of 2 0 0 hours. T h i s w a s obviously
a significant s a v i n g , particularly in v i e w of
the fact that the 4 0 , 0 0 0 terminations w e r e
very nearly duplicated at the mimic a n d data
logger.
T h e use of 5 0 core cables, w h e r e possible,
obviously offered major savings in terms of
service space required and cable installation
time.
Conventional armoured cables w e r e e m -
ployed in the open areas of plant w h e r e the
probability of damage exists.
M o t o r control centre (Fig. 37)
Motor control centres w e r e designed and
manufactured in s u c h a manner as to facilitate
expedient component c h a n g e . To this e n d the
smaller motors ( u p to 3 7 k W ) being in the
majority, and subject to a greater number of
operations, w e r e equipped with completely
w i t h d r a w a b l e starters. With this facility it is
possible to c h a n g e the complete starter
module in less than t w o minutes.
Interfacing the motor control centres to the
relay racks w a s a c h i e v e d by the use of
encapsulated pluggable 4 8 volt D C relays
w h i c h s w i t c h the 1 1 0 volt A C via interposing
relays, 1 1 0 volt A C being the operating coil
voltage of the 5 5 0 volt A C motor starter
circuits.
Advantage w a s taken of the large quantities
of starters involved to m a s s - p r o d u c e from
jigs all metalwork, bus-bars and associated
support components.
Transformers
A load analysis on the basis of 0 . 5 5 a m p per
k W indicated that it w a s necessary that the
lines each required 1 . 6 M V A transformers.
However, this a l l o w e d a negligible amount
decided that 2 M V A units should be installed. 1 3
 Credits
F i g . 38
Client:
Treatment plant
transformer yard
as S h a b a n i and M a s h a b a M i n e s ( P r i v a t e ) L t d .
are the o w n e r s and operators of S h a b a n i
Mine. A f r i c a n Associated M i n e s (Private)
Ltd, are Secretaries and Consultants to
S h a b a n i and M a s h a b a Mines ( P r i v a t e ) Ltd.
Project management:
M.G.Webber,

if
T e c h n i c a l director
Design leader:
H . J . C Shone,
M e c h a n i c a l engineering consultant

Electrical design:
J . M. Pattison,
Electrical engineering consultant
Mechanical and electrical installations:
M. L e w i s ,
F i g . 39 Chief construction engineer
Typical arrangement
Commissioning:
of connections
J . Scholz,
to 2 M V A transformers
Chief construction engineer
(HV&LV)
Consulting civil, electrical and structura
engineers:
Ove Arup & Partners
Project partners:
R. A . Heydenrych
E.S.Walker
Project structural engineer:
1
M. B . Noyce *
Project electrical engineer:
H. P. G i l l '
Project civil engineer:
J . P. C a s s o n "
Project co-ordinator:
A. R. Allester
Senior resident engineer:
T. E. H. F a w c e t t "
"Authors of this J o u r n a l assisted by J . E.

3
F i g . 40 Goddard and R. M. L a m b .
31 panel 11 kV
main switchboard Consultants to Ove Arup B Partners
Quantity surveyors:
J . M. C o o m ( P a r t n e r ) ,

1
J.Thrasher (Partner),
Walter S i m p s o n , C o o m and Morant
Architect:

ILT.
M. N. Clinton ( P a r t n e r ) ,
Clinton & E v a n s

Main contractors for civil and

structural works:
Grinaker Construction Africa ( P t y . ) Ltd.
General manager, construction:
T. N. v a n der Walt

Construction co-ordinator:
L. A . G l u c k m a n
Project site manager:
In the interests of interchangeability and the T h e 4 > 4 M V A banks are automatically H. de Bruyne
effective utilization of spares, these units were s w i t c h e d by reactive power relays. T h i s is Site manager, construction:
used throughout w i t h the exception of the necessary, particularly as the plant may be J . Armstrong
larger ( 3 M V A ) 1 1 , 0 0 0 / 3 , 3 0 0 volt units run in sections, w h i c h w o u l d lead to over Site agent, construction:
needed to operate the main fans and m i s c e l - correction and subsequent over voltage, in R.Allen
laneous other units for lighting and services the event of too much reactive power being
( F i g s . 38 and 3 9 ) . inserted ( F i g . 4 0 ) . Electrical contractor for treatment plant
power installation:
Lighting small power
Conclusion Electroreps ( P v t . ) Ltd.
T h e lighting system allowed for a basic level
T h e s u c c e s s of any project depends mainly Director:
of 3 0 0 lux, supplemented in areas considered
on teamwork. A A M leadership and design M. Guard
necessary. All fluorescent lights were fitted
skill formed the backbone of the entire Site agent:
with quick release gear trays and 5 amp plug
project team and the completed S h a b a n i Mill E. Gustafson
tops to a c h i e v e connection. T h i s a l l o w s
is a great credit to their organization.
removal/replacement by unskilled labour.
T h i s project is one of the biggest structures in Electrical contractors for treatment plant
Reactive power installation lighting and small power, plus complete
Z i m b a b w e and it s h o w s that even large
The Z i m b a b w e scale of tariffs for the supply of projects like this c a n be s u c c e s s f u l l y c o m - installation for feed system:
electricity is based upon an annual charge for pleted w i t h the minimum expenditure of H.W.S. Contractors ( P v t . ) L t d .
the m a x i m u m demand value reached at any foreign currency providing the right use is Manager:
instant during the financial year. made of local resources. There is no doubt J . Barker
With anticipated values in e x c e s s of 4 2 M V A , that, like the King Mill before it, it will benefit Site agent:
uncorrected and calculated m a x i m u m of not only the people in the area but also the P. B i n n s
+ 3 6 M W , the capital costs of the reactive entire country. For all those involved in the
power installation ( 1 6 M V A ) will be offset design the experience w a s challenging, Photos: Bob Davey,
1 4 in the first t w o years of operation. interesting and above all tremendous fun. (except w h e r e otherwise credited.)
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