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Portal 3 Stockpile Dome Cover

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About the project

Multi-party collaboration at its best

FL Smidth completed the structural design of the Stockpile Dome Cover.

The structure consisted of twelve main boxed gantries, 2.5m deep x 2m wide x 54m long. The twelve boxed gantries are welded to base plates on the concrete plinths at the base and bolted to a 7m dia center ring at the top. This structure covered the Mine’s main ROM stockpile with a capacity of 13 000t. All work was carried out around the already-installed Stockpile Feed Conveyor. The Mine and Stockpile Feed Conveyor continued to operate during night shift operation throughout the installation period – safety measures were of paramount importance.

Viva Engineering was responsible for the shop detailing, fabrication (manufacturing), trial assembly and transport to site.

The state-of-the-art FICEP SP16T6 CNC Anglematic was used in the manufacturing of the dome and resulted in the CNC department completing material preparation three weeks ahead of internal planning.

Trial assembly of two main gantries with the lattice infill steelwork between the two was completed in two weeks and without a single modification having to be made.

31 vehicles were used, including abnormal load vehicles, to deliver the structures to site within nine days of dispatch.

On-site installation was carried out by Hogarths’ experienced and skilled team. Key features of the installation include complex tandem lifts while a third crane was holding the center ring in place. Installation was completed with the mine not losing a single day of production.

Viva Engineering and Hogarths – providing turnkey supply and installation solutions for projects across Zimbabwe.

What they're saying

FLSmidth’s experience in dealing with Viva Engineering as their steel fabricator for their projects as well as their highly competitive fabrication pricing made them the obvious choice during the adjudication in a tender for a dome steel structure for a stockpile cover for one of our clients. We knew we had to partner with a fabricator that will provide something more than the average steel fabricator. We needed someone that understood the complexities of the structure that would have to be designed and fabricated keeping in mind that the structure would have erected safely in an operational production area of the client’s operations.

Viva Engineering was enthusiastic and creative during the partnership, from the onset we interacted and looked at different design approaches, fabrication requirements and most importantly construction limitations and considerations to ultimately develop the best possible design that limited production interruption, but also allowed the construction company to erect the structure safely. Viva listened to the constructor’s concerns during the design phase (Construction Risk Assessments) and made practical suggestions to the design and construction philosophy that would aid the constructor in erecting the structure safely.

Due to the short erection window, we had to ensure that all the steel components fitted precisely and within tolerance limits, for this we had to do trial assembly of the main portions of the structure. The problem with this was, that due to the physical size of the structure, even trial assembling a portion of the structure proved to be a challenge due to the real estate required to do this. Viva however did not shy away and was able to find a suitable area big enough to safely perform the trial assembly. The trial assembly was done seamlessly with minimal tweaks required. The steel was then shipped cross border to our client’s site on time. The efforts in the early involvement of Viva into this project showed, and the structure was built in time without a single injury on the constructor’s side. The client was very satisfied with the result and it is truly a very impressive structure to behold.

I would like to thank the entire Viva team for your positive energy, can do attitude, professionalism and commitment to deliver on time. It is a great experience when your partners are just as serious about your projects as you are.

Martin KrugerEngineering Manager, FLSmidth – Plant Systems

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