AMT: Jan/Feb 2010

Advanced Materials Today Jan/Feb 2010

Jan/Feb 2010
Contents
KEW Foundries Cover Story Design Companies and Software
Tel: (053) 841-0474 4 KEW Foundries – Casting Excellence Programmes
Fax: (053) 841-0473 24 Red Hot Manufacturing Software
Email: Stockists and Service Centres
john@kewfoundries.co.za 8 Ready to Steel Market Share Customising
Website: 27 Hot Iron, Shiny Wings and a Highway to
www.kewfoundries.co.za Machining Heaven
10 Pimp my CNC Machine
International News
Castings, Forgings, Furnaces and 33 International News
Refractories
12 Change Founded in Adversity Industry News
36 Industry News
Industry Leaders Profile
14 Raw Energy Drives Power Supply Endorsing Bodies
Project • SAIMechE (SA Institution of Mechanical
Engineering)
Alternative Materials
21 Ancient Wonder Material • AFSA (Aluminium Federation of SA)
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COVER STORY
KEW Foundries – Casting

Excellence
KEW Foundries, South Africa’s oldest foundry and an international supplier of a wide range of cast products,
recently completed its largest casting project to date – the manufacture of bearing swivels and main trunnion
bearing housings, with the bearing housing base alone, weighing 6450 kilograms. The castings, which re-
quired a challenging two ladle pour, were manufactured for New Concept Projects and will be used on a 2800
kW ball mill, being supplied to El Brocal for the Huaraucaca project in Peru.
T
he bearing swivels were cast in SG 60 iron, ing products from all grades of SG iron and grey
while the bearing housings have been manu- iron in order to capitalise on the many benefits
factured using 250 grade grey cast iron. The that the materials provide over steel. According
housings have a 2160 mm diameter and to John Bryson, foundry director, KEW Foundries,
are 813mm wide. The housings will operate with a the company’s use of SG iron in its casting work,
lead bronze bush bearing in a hydrodynamic bearing represents a shift in typical production methods
assembly. The bearings will be required to handle which has inherent benefits for clients. “The market
loads of up to three hundred tons each. place is now awakening to the benefits of using SG
iron castings due to the lower prices associated
KEW Foundries has standardised on manufactur- with casting and the reduced machining costs.
Steel castings can take up to two years to deliver,
whereas KEW Foundries can supply SG iron cast-
ings in a matter of weeks, including machining and
pattern manufacture.”
The company also conducts
non-destructive testing in-house, using
magnetic particle, die-penetrant and
ultrasonic testing methods
KEW Foundries manufactures a wide variety of
products cast in SG iron, including solid sheave
wheels, gearbox castings, bearing housings, valve
bodies and discs, fly wheels and other crusher
parts, slag pots, chill moulds and small to large
pump casings.
To accomplish the manufacture of a high quality
product range the company’s manufacturing plant
comprises foundry equipment, a machine shop and
laboratory testing facilities. The foundry features two
furan sand foundries which are capable of produc-
ing castings from 1 kg to 7 500 kg, in both single
and complex shapes. The foundries are supplied
with metal from a 6 000 kg induction furnace and
either of the company’s two 3 000 kg furnaces
feeding off a common power pack. The machine
shop is fully equipped to enable it to undertake
almost any machining application.
Quality standards are maintained using laboratory
facilities equipped with an extensive arsenal of testing
equipment. Equipment includes an ARL 3460 Ret
B optical emission spectrometer, a metallographic
testing division and a sand testing section. The
KEW Foundries recently cast the largest sheave wheels ever manufactured on company also conducts non-destructive testing in-
the African continent with an outer diameter of 21.5 foot house, using magnetic particle, die-penetrant and

COVER STORY
ultrasonic testing methods – to ensure that clients

receive quality products free of defects.
To ensure the ideal casting is manufactured for
each and every application, KEW Foundries has a
dedicated design department capable of advising
and collaborating with clients, or working autono-
mously, to achieve application specific designs.
Accompanying this is an extensive pattern library,
as well as the facilities and expertise to design,
manufacture and store unique client patterns.
KEW Foundries is making innovations

which increase personnel safety while
reducing unscheduled downtime
At KEW Foundries’ manufacturing facility, quality,

delivery and co-operation are the three elements
which form the basis of the company’s service
offering. “As a supplier to various industries, we
are always evaluating and expanding our product
range, testing its quality and ensuring that we run
the most efficient operation possible,” says Bryson.
The company prides itself on developing lasting
client relationships, built on unrivalled service and
delivering high quality solutions with an emphasis
placed upon product reliability.
Sheave Wheels
In addition to the foundry side of the business,
KEW Foundries has a dedicated department for
manufacturing and machining sheave wheels, and
currently holds the title of Africa’s sole manufacturer
of large, cast headgear sheave wheels. A completed valve body ready for final assembly
KEW Foundries’ sheave

wheel solutions feature an
80 percent grey cast iron
construction. The compa-
ny’s design criteria differ
from conventional sheave
wheel designs, which utilise
welded assembly construc-
tion methods.
Jamie Goncalves, technical
director, KEW Foundries,
says that a cast sheave
wheel design is more robust
and delivers a solution
which requires less main-
tenance. “Our cast sheave
wheels are just one example
of how KEW Foundries is
making innovations which
increase personnel safety
while reducing unsched-
uled downtime. Sheave
wheels are safety critical
components and, by their
very nature, are subjected
to heavy loads under harsh
operating conditions. Our With an extensively equipped machine shop KEW Foundries is capable conducting all machining work on-site,
including the machining of large sheave wheels

COVER STORY
sheave wheels feature a bolted assembly which

is highly resilient to operational stresses. By
comparison, sheave wheels which make use of a
welded assembly develop stress cracks which need
to be continually maintained. With safety critical
components, reliability becomes imperative. Our
sheave wheel solutions also improve operational
productivity as a direct result of the reduction in
unplanned downtime.”
Recently KEW Foundries designed and manufac-
tured the largest cast sheave wheel ever assembled
on the African continent – a 21,5 foot (6,5 metre
diameter) wheel to be used as part of a cluster
arrangement on one of the new platinum mines in
the Phokeng area.
KEW Foundries’ sheave wheel range includes
headgear, dragline doubling down, compensating,
kibble and stage sheave wheel assemblies for both
opencast and underground mining. In addition, the
sheave wheel division offers on-site checking and
re-conditioning of existing installations.
It has developed a “best of
specification” for its sheave wheel
solutions
Goncalves notes that as a result of the company’s
extensive industry experience, and its strong re-
KEW Foundries manufactures a wide variety of bearing housings suitable to a
lationships with mining houses, it has developed multitude of applications
a “best of specification” for its sheave
wheel solutions. “We have taken the
best requirements of the mining house
specifications to produce sheave wheels
and related equipment that meets and
even exceeds our clients’ requirements.
KEW Foundries’ specifications have been
adopted by a number of mines that were
without a detailed specification.”
KEW Foundries’ is strategically based in
Kimberley on the national grid, creating
fast and efficient access to Johannesburg,
Cape Town, Port Elizabeth and Durban.
This ensures fast movement of products
for export. The company also operates
its own fleet of vehicles, with purpose
built trailers, in compliance with the
road act, that ensure timeous deliveries
into sub-Saharan Africa. KEW Foundries
regularly supplies cast solutions to clients
in global arenas, with recent casting be-
ing delivered to India, Russia, Zambia,
Australia, America, Canada, Chile, Ghana,
Finland, Tanzania, Angola and Namibia.
The company has the core capabilities
and the ingenuity to supply cast solutions
to anywhere in the world.
KEW Foundries, John Bryson, Tel: (053) 841
0474, Fax: (053) 841 0473, Email: john@
kewfoundries.co.za, Web: www.kewfoundries.
co.za KEW Foundries’ largest casting to date - a bearing housing to be used on a 2800 kW ball mill.
The base alone weighed a staggering 6450 kilograms and required a two ladle pour

STOCKISTS AND SERVICE CENTRES
Ready to Steel Market

Share
Kulungile Metals Group (KMG) CEO, Sampie

van Rooyen
Metals are cut shaped and sized at the KMG Service Centres
Kulungile Metals Group (KMG) has a bullish outlook on the year ahead
with bold plans to expand its offerings to clients through value added
services and the possibility of an expanded footprint in new centres
around the country. Having emerged from the recession in good shape
and with a healthy balance sheet, group executives are scanning the
aftermath of the economic downturn eager to expand through acquisi-
tions or to fill voids left by those that did not survive last year’s cruel
blows.
S
hrewd management either service enhancing machinery or businesses
of its resources has that fulfill the needs of the organization.
left the company in He predicts that stockists will come under pressure as
a position to go into the market turns positive and that required restock-
the new year with a plan ing will drain the financial resources of especially
that centres around provid- the smaller stockists or those that have not been
ing superior customer ser- prudent in the management of cash.
vice. Chief Executive Officer,
Johan Foord is a divisional director of KMG Sampie van Rooyen, says the “We will certainly be on the look out to acquire
main area of growth will be to enhance offerings businesses that add value to our customers and
at its existing service centres around the country that fit into our growth strategy. We will also move
and to ensure customers can access all their met- quickly to fill voids left by those stockists that either
als requirements at KMG without the need to shop can’t replenish stock in time or that fold under the
around. Simultaneously the company will itself be financial burden.
shopping around for value adding acquisitions of Investment
Restocking will drain the financial resources of Notably the group has recently invested in machinery
and equipment that will enable service centres to
especially the smaller stockists handle higher volumes of work through the service

STOCKISTS AND SERVICE CENTRES
centres. The ability to cut, drill and machine metals Stockists in the country with branches in Isando,
received in coil, plate and structural steel sections Germiston, Vanderbijlpark, Welkom, Cape Town,
of varying thicknesses has been enhanced with the Worcester, Port Elizabeth, Pinetown, Durban Central,
addition of high definition plasma cutting machine Meyerton, Richards Bay and East London. Where
that cuts precise forms up to 80 mm thick. Three services are not available locally the materials will
lazer cutting machines are in operation, while be prepared at the main branch and sent to the
less precise work can be cut on gas fuel cutters services centre nearest the customer.
or guillotines. Kulungile Metals Group, Susan van der Westhuizen, Tel:
A new vertical machine centre has just been in- (011) 929 5134, Fax: (011) 929 5159, Email: susanvdw@
stalled at the main Isando branch, while a high kulungile.co.za Web: www.kulungile.co.za
pressure 600 ton press break is being installed
for up to 5 m bends of plate up to
95 mm thickness. New drills and
rolling machines will be brought
on line through the year to enable
drilling and rolling of structural
steel. The additional services will be
made available to clients throughout
the country through KMG regional
service centres.
Services
On a recent tour of KMG’s main
Isando branch Advanced Materials
Today asked divisional director, Johan
Foord, how the company differentiates
itself from the competition.
All the client had to do on
site is piece together the
puzzle and join it
“We maintain our stock of carbon,
stainless steel and aluminium at
optimal levels so customers are
assured they get what they need
when they need it. The metals are
A decoiling machine prepares rolls for plate cutting
available in coils, flat plate or struc-
tural steel lengths and customers
can take delivery of their material
requirements in the manner that
best suits them.
“The extend of our services ranges
from decoiling and cutting steel into
manageable plate sizes to the full
treatment where we take care of
design requirements, cut profiles and
drill the metal ready for assembly.
Structural steel can be cut, drilled
and bent to shape. The client can
specify the techniques used to ensure
ease of assembly of the completed
shapes,” Johan says.
He quotes an example where a com-
plete boiler was designed, metals
supplied to specification, profiled
and cut to requirement. “All the client
had to do on site is piece together
the puzzle and join it.
Branches
KMG is one of the top three metal One of KMG’s plasma cutters

MACHINING
Pimp my CNC Machine

Those that have watched the popular ‘Pimp my Ride’ series on China and elsewhere in the East and the market
television can appreciate the kind of work that goes into re- was becoming saturated. In many instances the
building, re-fabricating and upgrading something as simple as machines landed price was cheaper than Efamatic’s
a motor car. By comparison ‘pimping’ or retrofitting a massive cost of materials and they foresaw a shrinking
10-ton precision CNC controlled vertical or horizontal lathe market share.
that houses a sophisticated network of hydraulic and pneu- Two years ago they took the bold decision to diver-
matic mechanisms and accompanying electronics for machine sify into the refurbishment of worn-out machines
tools, you can imagine that the job is so much bigger and and began rebuilding and retrofitting them from
more complex. the ground up. At the same time they also began
A
marketing Efamatic’s ability to build custom or
lthough not quite as glamorous as turning special purpose machines for clients anywhere on
out a V8 American hotrod, the end product the globe. The new ventures took off and Efamatic’s
of refurbishing a large CNC machines is team of design engineers and technical experts
nonetheless still an impressive sight. Mike have been redeployed to lend their expertise to
Faccio, who jointly owns Efamatic Machine Tools giving clients what they want. It’s success has also
with his brother, Luigi, is growing accustomed to spared the company from the fall-out of the global
the wisdom of the old saying ‘out with the old, in economic recession.
with the new’. No reality show
Like the machines that he refurbishes Mike found On the TV show a car is presented to the chief
two-years ago that their business was in need of a engineer and a list of requirements presented.
make-over. As the only manufacturer of CNC ma- The design team then go about their business
chines in South Africa, Efamatic had built a proud and present final drawings and specifications to
reputation for quality and service. Local customers the technical team that go about building it. After
bought the machines safe in the knowledge that the much panel beating, chipping, painting and fitting
home-grown technology would be well supported the car is ready to go to the handover. Here the
by the company’s team of experts and that spares owner is presented with the shiny ‘new’ car and
were readily available. after a flood of tears and thanks he or she usually
disappears down the road and into the sunset to
But, Efamatic found the tide was turning. Floods of
enjoy the freedom of the road.
cheap machines were arriving on our shores from
Floods of cheap machines were arriving on our shores No such glitz and glamour exists in the refurbish-
ment of CNC machines. Rather, Efamatic is usually
from China and elsewhere in the East given the machine by a client that has a
specific goal in mind. They usually present
them with hard facts and data sheets that
relate to the required performance of the
machine and the kind of items that will be
turned out.
At this point Efamatic thoroughly inspect the
machine to assess the condition and decide
what stays and what must go. “Sometimes
all we can reuse is the frame and a few
components, while other machines may
require fewer new parts, but more conver-
sion,” says Mike.
Process
And, so the transformation begins, each
and every part and component needs to be
removed or cleaned for a thorough inspection
to take place. Failures or potentials flaws
are identified and replaced or repaired as
necessary. “The whole point of refurbishing
a machine is to make it as good as new or
better than the original. If you don’t check
Mike Faccio, managing director of Efamatic Machine Tools, next to the unusable parts from a every part and assess the risk of future fail-
CNC machine that is being rebuilt
10 Advanced Materials Today Jan/Feb 2010

MACHINING
ure you are building a machine that may fail sooner

rather than later. You have got to remember that the
machine is as good as its weakest part so you can’t
afford to overlook anything.”
All beds get reground to specification, ball screws are
fitted and all wiring and harnesses replaced. A new
CNC control package with new motors and drives is
installed, along with hydraulics and lubrication. Fol-
lowing this new covers are put on and the machine
is finished with a vinyl sticker proclaiming that it
has been refurbished by Efamatic. On the day of the
delivery the tears of joy are normally reserved for
the moment at which the bill is presented and the
customer realizes that he is saving two thirds of the
purchase price of a new machine.
Yes we can
In just two years Efamatic has turned its entire rev-
enue model upside down. Where it previously derived
almost 100% of its revenue from sales of its range
of CNC machines, this now accounts for only 30%
of its current revenue. New markets are accounted
for by refurbishments (40%) and custom solutions
(30%). Refurbishment makes sense in current market
conditions where money is tight. But, custom-building
machines is an altogether different market. It is less
affected by price, as manufacturers from the East are
not likely to manufacture machines on a one-off basis.
At this end of the market customers are prepared to
pay for engineered quality solutions.
Refurbishment makes sense in current

market conditions where money is tight
The same highly-skilled team of engineers that con-

ceptualised, designed and produced the company’s
latest range of machines are not sitting idle. Instead,
they are busily employed interpreting customers’
requirements, designing and building machines to
their varied requirements. “From specialized machines
that turn out artillery shells to shock tube coiling ma-
chines – we do it all. Just like Barak Obama we have
adopted the saying ‘yes we can’! When a customer
asks whether we can build a machine that does ….,
the answer is an unwavering yes we can.
Mike points out that some of the customized ma-
chines the company built over the past two years were
shipped to destinations abroad with a high number
of machines built for clients in the United Kingdom
and South America. Thanks to Efamatic’s foresight
the company has spread its wings and expanded its
horizons.
Efamatic Machine Tools, Mike Faccio, Tel: (011) 626-2720,
Fax: (011) 626-2966, Email: mike@efamatic.com, Web:
www.efamatic.com
Advanced Materials Today Jan/Feb 2010 11

CASTINGS, FORGINGS, FURNACES AND REFRACTORIES
Change Founded in
Adversity Foundrymen
are a breed apart when it comes to
dealing with tough conditions. After all, the foundry
is no place for sissies. Mess with their livelihood and you
W
can rest assured that this breed of person will not take it
hen world eco- lying down, rather they’ll choose to fight it out until
nomic events sent some sort of resolution is found.
our market into a freefall
one of the worst affected sectors
of the manufacturing industry were the foundries.
Collectively estimates indicate a 40% dip in year-
on-year revenues. Those with a large reliance on
the automotive and mining industries – two markets
that were worst hit by the recession – were par-
ticularly hard hit. After the initial shock of losing so
much business so quickly, Rely-Intracast, a leading
investment casting foundry based in Boksburg
and one of those affected by the recession, tells
Advanced Materials Today how it has emerging
from the recession fighting fit.
“In the beginning of the year we were taking a
We went from running double shifts to laying off 28

staff members almost overnight, a painful testimony of
how deep the recession was cutting
battering and orders for parts for the mining and

automotive sectors were all but dried up. This liter-
ally forced the company to its knees and emergency
restructuring and retrenchments were the order of
the day. We went from running double shifts to
laying off 28 staff members almost overnight, a
painful testimony of how deep the recession was
cutting.
“The outlook was bleak and on a daily basis we
were faced with downscaled or cancelled contracts.
It became a battle for survival and we weren’t about
to shy away from the challenge,” says managing
director, Mark Hughes.
New proposition
Instead, he says, the company management and
staff knuckled down and relooked the business from
the ground up. Where extra efficiencies could be
implemented they were, but the biggest change came
in the form of a new proposition to the marketplace.

CASTINGS, FORGINGS, FURNACES AND REFRACTORIES
The proposition was centred on the company’s skills The biggest change in the company is our new-found
and technical ability and finding new customers hunger to explore and find new markets to operate in
that can benefit from its offerings.
Exploring
Rely-Intracast is part of the Pamodzi Industrials “The biggest change in the company is our new-
Group and has access to a vast array of technical found hunger to explore and find new markets to
skills within the group, as well as a healthy customer operate in. We have moved from an introverted
base. Sales and marketing strategies were laid and narrow focus to an all inclusive extroverted ap-
are currently bearing the fruit of the companies proach to expand our markets. We are proud of
shift in focus. “We are playing to our strengths as the fact that we are able to work with almost any
a foundry that is able to cast almost any product material and are able to cast almost anything that
in nearly every known alloy available. the customer needs. That is something to be proud
Lost wax of as there are not many companies out there that
We are proving to manufacturers that lost wax can boast the same kind of diversity of products
investment casting can provide them with precise as we can. When the recession is finally over we
parts or products without the need for further fin- will be in a stronger position and will have a bigger
ishing or machining. In some instances our clients footprint than we did before. I believe we have come
are amazed to see that we are even able to cast out fighting and have conquered the recession,”
relatively fine threads and precise parts for all sorts concludes Mark.
of applications. Rely Intracast, Mark Hughes, Tel: (011) 914-1640, Fax:
Mark continues that the recessionary market has (011) 914-3586, Email: mark@rely.co.za, Website: www.
rely.co.za
affected manufacturers across the board and says
that a number of clients have been forced
to downsize operations.
“The economic climate is forcing companies to
relook at the way they do things. As a result
an increasing number of new customers are
approaching us to cast parts and products
that were previously being machined. By
casting the goods the companies are able
to save on workshop costs by eliminating
the need for machining and finishing. This
translated to a significant saving on man-
power costs and equipment.”
Sales
The company’s sales force is actively target-
ing manufacturers of products where casting
makes sense. They are able to go into the
market with renewed vigour and propose
win-win proposition for companies and
propose a multitude of materials that can
be used. Rely-Intracast metallurgists will
either match the materials currently being
used or where necessary will formulate
alloys that are best suited to the products
intended application given environmental
and cost constraints.
During the year the company has also
undertaken initiatives to better service its
existing clients in the automotive, mining,
glass, defence, railways, fluid control, en-
gineering and power generation industries.
New power station developments, as well as
exciting plans in the automotive industry are
giving the company reason to celebrate and
the evidence of a recovery in all segments
is already being felt. To a large extent the
future of Rely-Intracast has been remoulded
through the recession.

INDUSTRY LEADERS PROFILE
Raw Energy Drives

Power Supply Project
As a low-key visitor to Steinmüller Africa’s Pretoria-based workshop it was striking to note the intensity of the
workers going about their business of fabricating the boilers, auxiliaries and pipework that will power Eskom’s
two new coal fired power stations and relieve the energy crisis that is gripping South Africa. In all my years
visiting factories and worksites I have never witnesses such focus nor sensed such pride in the work being
carried out.
I
t may have been a good day, or more likely it Under the umbrella of its German parent company,
may be that the company’s workforce under- Bilfinger Berger Power Holding, it is part of one of
stands the gravity of the power situation in the world’s leading industrial groups with a history
South Africa and feels that they are in their own spanning nearly 150 years in power generation.
way providing a patriotic service to their country. Evidently, the group’s vast experience and deep pool
Nonetheless, the task at hand is enormous the of skills will be taxed to the hilt in the years leading
scale of which has never been undertaken in such to the completion of the fabrication project.
a short time by a single company anywhere in the Few people outside the energy sector in South
world – ever. Africa realize the scale of Eskom’s ambitious plans
Few people outside the energy sector in South Africa to build two massive new coal fired power stations
realize the scale of Eskom’s ambitious plans by 2014.
Parts and pressure parts for the new power stations

Super-critical
On completion the power stations will be the largest
on the African continent and their modern designs
will ensure maximum efficiency. The stations’ boilers
operate at super-critical temperatures (above 500° C)
in order to get the most out of each ton of coal that
is burned. The high temperatures and subsequently
high pressures call for super strength exotic materi-
als to be used.
Salvador von Neuberg, director of Bilfinger Berger, is
in charge of technical operations of Steinmüller Africa.
He explains that the scope of work is enormous and
highly specialized. It entails hundreds of kilometers
of piping and high pressure piping made from exotic
materials to be imported and transported to the site
for bending and welding.
A ceramic header pipe
In turn, thousands of kilometers of specialized welds

will be made by hand or machine and fabrication
of the huge boilers and walls is well underway and
will be an ongoing process over the next four years.
Absolute precision is called upon for all processes
to endure the extremes of power generation and to
ensure the 30 plus year life expectancy of the power
plants are met.
The main workshop is some 800 m long to

accommodate the boiler walls laid
end-to-end
Pretoria workshop
When the company was awarded the Eskom contract
it became apparent that new larger premises would
be needed to house the operation. The mostly disused

premises of Arcelor Mital (previously Iscor)
were ideal due to the size and nature
of the buildings and its location in the
heart of the capital city’s industrial area
is central for supply operations.
The main workshop is some 800 m
long to accommodate the boiler walls
laid end-to-end. Cutting, bending, weld-
ing, and preparation of the thousands
of metres of pipes and fittings is done
on machines that have been specially
installed for the purpose. Prefabrication is
carried out in one of two slightly smaller
workshops where specialised equipment
is also housed. The new workshop totals
an enormous 60 000 m² under roof and
brings the groups total workshop area
to a staggering 102 000 m². The prem-
ises are equipped with fit-for-purpose
machines and the entire operation runs
efficiently through the workshop with
little wasted space.
More than 5% of the

company’s workforce is
employed in a role directly
related to ensuring quality
South African footprint

Steimuller has long history in the country.
In 1896 the company supplied an 8
MW steam plant for the Brakpan Power
Station. In 1962 the Steinmüller group
established itself in South Africa and
since then it has provided the steam
generation systems that powers most
of the country’s coal fuelled power sta-
tions. It is also responsible for long-term
A mill similar to this will be installed at Madupi Power Station maintenance on more than 80 % of
the plants locally and many more
across our borders.
Steinmüller’s maintenance division
currently keeps the generation side
of most Eskom’s power stations
in ship-shape condition and the
company has recently been called
upon to recommission several of the
power utility’s mothballed plants
to fulfil the country’s burgeoning
power requirements.
Complete maintenance solutions are
currently being provided for Arnot,
Hendrina, Duvha, Kriel, Tutuka,
Majuba, Camden, Grootvlei and
Komati, Matia and Matimba (pip-
ing only) have partial outsourced
maintenance contracts. Plant lifetime
extension are also being provided
on certain power stations.

Equipment
· Water Wall Panel fabrication line
· Fin calibrating and shot blasting equipment
· Beveling machines for Edge preparation
· Electric PWHT Oven up to 1 150oC, 2m x 2m x 10m
· Automatic Butt Welding m/c. for tube dia up to 88.9mm
· Automatic Supporting Tube Welding m/c. (CO² process)
· Header Nipple Welding m/c. with 2 TIG & 3 Subarc torches
· Subarc Welding Equipment with Manipulator up to 1 100 A
· CNC Booster Bending m/c. up to 120 mm tube dia
· Booster Bending m/c. up to 63.5 mm tube dia
· Mandrel Bending m/c. up to 133 mm tube dia
· With 6 Torch operation the current Capacity of the Panel Welding Machine is more than
3 000 weldmeter/shift
· Working 20 days/month it can achieve 40,000 to 60 000 weldmeter/month
· Under consideration of approx. 70 subarc meter/m² wall it may perform 600 to 900 m²
Water Wall Panel per month as a minimum
· Membrane welding machine, 6 head, 2.5 m x 30 m, 20 000 weld metres a week
· Header Nipple Welding m/c. with 2 TIG & 3 Subarc torches
· CNC Header Drilling m/c.
· 3 x Cold Bending m/c for up to 5 000 bends a week
· Automatic Sling Tube Welding m/c. (CO² process)
· Automatic Butt Welding m/c. for tube dia up to 88.9mm
· Induction bending machine up to 850 mm dia
· The bending machines are capable to bend in 2-shift operation at least 800 bends/day, as
a maximum per day approx. 2 000 bends
· During 20 days/month it may achieve 16,000 to 40,000 bends/month
· Under consideration of approx. 4 m tube length per bend it may perform 80 000 m of tube
per month as a minimum
Heart of the company

According to Salvador the com-
pany is built around its people
and thrives on the ability to call
upon the skills of its trained and
talented workforce. The South
African operation boasts more
than 100 engineers and other
suitably qualified technical staff
out of a total workforce of about
800 people. Furthermore, the
company recently acquired a
technical skills training institu-
tion to provide on-site training
and facilities for artisans and
technical staff to ensure they
are equipped with the necessary
know-how to undertake tasks
that are assigned to them with
confidence.
“Steinmüller Africa is a world-

class organisation that sets high standards

for its staff and suppliers in order to meet
and exceed customer expectations on an
ongoing basis,” Salvador adds.
While Steinmüller has the pedigree and
skills to undertake the challenging tasks at
hand, its vision is to remain the preferred
supplier of project management, engineering,
maintenance and construction services in
southern Africa through the group’s com-
bined operations.
Expansion into other projects on

the continent are on the cards
Principals
A common thread that runs through all the
group companies is an uncompromising focus
on quality. Quality of materials, services
and supply ensures a continuity of quality
products and services. More than 5% of
the company’s workforce is employed in a
role directly related to ensuring quality. Ad-
ditionally, all supervisors and line managers
have additional responsibilities related to
maintaining quality and it is safe to assume
The induction inlet on a typical power plant

Soon to be commissioned induction bending machine
that the work is of the highest standard. Apart from trained staff and the highest quality
“In order to be a world class operation we employ accreditations the company expects similar quality and
business principals that ensure we employ the best service levels from its vast supplier base
technical expertise, use the best quality materials
role-player in the Southern Hemisphere. Expan-
and have a workforce of well-trained artisans to
sion into other projects on the continent are on
complete every task. This quality ethos is enshrined
in everything we do and incorporates everyone from
supply to final handover. In this way we are sure
of our outputs and clients can rest assured they
get what they pay for.”
Quality is king
True to its German origins and German tradition the
company is centred around quality of workmanship.
It has ISO 9001: 2008 accreditation for design,
service, maintenance and refurbishment of steam
generators, pressure parts and related inspection
activities and services, while the Steinmüller Africa
Workshop has recently achieved ISO 3834 accredi-
tation. The accreditation also covers portfolio of
industrial, petrochemical and pulp & paper products
such as pressure vessels and other fabrication and
engineering services.
Apart from trained staff and the highest quality
accreditations the company expects similar qual-
ity and service levels from its vast supplier base.
To supply products or services to the group is a
feather in the cap of any company that is on their
supplier list as the same stringent controls that
govern the company govern suppliers. Most of the
capital equipment, machines and consumables
supplied are sourced through the parent company
in Europe, but a number of local suppliers have
received the nod to supplement supplies.
Future
Looking beyond the current Eskom projects the
company will be poised to take on work elsewhere
in the world and is positioned to become a major

the cards, where its expertise in the

supply of heavy engineering solutions
particularly power generation and
process plants, will be expertly
employed.
Supplier dynamics
Steinmüller Africa’s rigid focus
on quality transcends company
boundaries to its supply chain.
Suppliers are carefully selected
on quality and merits of their
supply and have under-
gone careful screening
through its procure-
ment department
before contracts are
awarded.
It is a feather in the
cap of the suppliers
as their services are
deemed to be of the
highest international
standards. In addi-
tion, the speed at
which the power
station projects are
Thousands of weld-kilometres will have been completed manually and by machine by the time
progressing means
the generation plant is commissioned
Steinmüller’s local power milestones

2004 : Camden Power Station - return to
service
2003 : Partnership contract with Eskom
maintenance services renewed
2000 : Partnership contract with Eskom for
maintenance at 8 power stations
1986 : Erection of 6 x 665 MW for Matimba
Power Station
1983 : 3 x 675 MW boilers and 3 x 711
MW boilers for Majuba Power Station
1980 : 6 x 600 MW boilers for Tutuka
Power Station
1975 : 6 x 600 MW boilers for Duvha
Power Station
1970 : 6 x 500 MW boilers for Kriel
Power Station
1968 : 5 x 200 MW boilers for Hendrina
Power Station
1967 : 200 MW boiler for Grootvlei Power
Station
that swift, on time delivery is the order of the day

and supplying the company really is a case of
survival of the fittest.
Steinmüller,Tel: (011) 806-3000, Fax: (011) 806-3330,
Email: info@steinmuller.co.za, Website: www.steinmuller.
co.za

ALTERNATIVE MATERIALS
Ancient Wonder Material

Imagine a high-tech material that combines phenomenal wear resistance with flexural strengths that are mea-
sured not in megapascals but rather in gigapascals, and consider its application potential within industry. A
material that is so advanced that it can be formed or moulded,
within limits, to almost any shape required and can withstand
temperatures far beyond that of most alloys. It can be produced
to be light weight, non-conductive or non-reactive or to suite
any application.
L
ook no further than your kitchen or bathroom
because the wonder material is collectively
known as ceramics and has been used by
man for thousands of years. Since intrepid
Chinese pottery makers developed techniques to
mould fine crockery, similar processes are still used
today to produce industrial ceramics with phenom-
enal properties. Fine China crockery, bowls, baths
and basins were popularized through the ages and
ceramics are now synonymous with kitchen and
Its popularity as a crockery and sanitary ware of choice,
though, has done little to further the cause of this
versatile material Martin Meyer, managing director of CERadvance
bathroom ware in house-

holds around the world.
Its popularity as a crock-
ery and sanitary ware of
choice, though, has done
little to further the cause
of this versatile material in
other applications.
Reputation
Thinking of ceramics you
usually remember mo-
ments when you smashed
gran’s best China din-
ner plate or cracked the
porcelain floor tiles after
your soccer ball sent your
mother’s favourite potplant
careening off the shelf.
Its reputation therefore is
of a dainty material that
breaks easily and is prone
to cracking and chipping
at the drop of a hat.
If ever there was a candi-
date for a classic misgiving,
then this is it. While most
ceramics are no-doubt
brittle, some nevertheless
rank among the toughest
materials known to man,
Sintering kilns for ceramic firing and provided good crys-

talline design principles are adhered to, they are

up to a lot more than most design engineers give Fact box
them credit for. Martin Beyers, managing director Look out for CERadvance’s new monetary cur-
of CERadvance Engineering Ceramics has devoted rency – the Duro. Like any currency it has a
his entire working life to disproving the myth and value that is based upon a promise to present
advancing the use of ceramics in new industrial the bearer a certain amount of real value. The
applications. South African Rand, for example, is based upon
Innovation gold and in theory the currency is redeemable in
The company he co-founded a decade ago bases gold should the reserve bank choose to reimburse
its product development on the adaptability of the bearer.
ceramics and providing ceramic solutions to an The Duro is no different. It is issued to users of
increasing amount of industrial problems. Through CERadvance’s Line-Ox ceramic products and
the innovative use of ceramics in appropriate ap- symbolically as well as in cost-saving terms
plications, using appropriate design parameters, promises to pay the bearer the equivalent value
the company boasts having saved clients a small in the most precious commodity of all, namely
fortune in process improvements and extension of reduced downtime and improved productivity on a
lifetime of machines and parts. cost-to-life basis. The clever marketing campaign
was launched by CERadvance at its 10 year an-
To compound the problem, few if any tertiary institution niversary earlier this year to represent time and
in the country include more than a fleeting mention of money savings enjoyed as a result of improving
ceramics in their curricula the lifespan of parts and components within
production processes through the appropriate
“Ceramics have gotten a bad rap in the last part of use of ceramics.
the previous century. To compound the problem,
few if any tertiary institution in the country include
more than a fleeting mention of ceramics in their “That’s why most applications of ceramics are
curricula. Students are taught of the properties of designed as a retrofit to solve problems where the
metals, polymers, even wood and the likes, but original material is inadequate, like in high wear-
not schooled on the phenomenal properties of ing or high temperature applications. Instead of
ceramics. designing machines or entire processes that include
ceramics where they can be used optimally we find
that engineers use materials that they understand
and have learned the properties of.
Only when poor performance or failure results, do
the engineers look towards using alternative materi-
als such as ceramics,” says Martin.
He insists that engineers should familiarize them-
selves with the properties of ceramics in order to
be able to confidently specify the right material for
the right job. The design of equipment and imple-
ments can then be carried out from scratch using
materials that are fit for the job in mind. But Martin
is realistic about the task at hand and is resigned
to the fact that preconceived ideas take a long time
to change. His outlook on the future of ceramics
is more like that of a teacher that patiently shows
the way and leads by example. He has set up an
on-site laboratory to conduct tests on ceramic
products and to provide conclusive evidence of its
performance in simulated applications.
Properties
According to one definition, ceramics are inorganic,
non-metallic compounds produced at ambient tem-
peratures and then heat-treated at higher tempera-
tures. Oxide ceramics used in industry are composed
of synthetically produced Alpha-Alumina, Magnesia,
and Zirconia to mention a few. Other compounds
can be added to provide different characteristics
required for different industries, such as electronics,

the strong and du-

rable material are
limited only by the
imagination and
although ceramics
have been used in
industrial processes
for many decades,
a myriad of appli-
cations can still be
improved through
the effective use of
ceramics. In this
regard CERadvance
has provided solu-
tions to many trou-
blesome problems
in many instances.
We have saved
companies a lot of
money and time and
will continue to do
so in future. Our
ceramic products
are being employed
in hundreds of dif-
ferent applications
from valve liners to
catalyst supports in
A selection of parts destined for industrial applications chemical treatment
plants, refractories
Once you understand the properties of for foundries and general wear components for the
ceramics you will find that there are mining sector. Once you understand the properties
millions of applications for the of ceramics you will find that there are millions of
applications for the material,” ends Martin.
material
CERadvance, Martin Beyers, Tel: (011) 397-8933, Fax:
structural or industrial. (011) 397-8938, Email: inquiries@ceradvance.co.za, Web:
The inherent strength of ceramics is derived from www.ceradvance.co.za
the tough covalent bonds and the densification
process, called sintering
through the application of
heat energy. Techniques
to minimise the crystal
size and improve bonds
are continuously being
developed and as a result
the density and strength of
ceramics can be manipu-
lated to provide a wide
range of characteristics.
Ceramics can deliver high
compressive strength, wear
resistance or wide-ranging
thermal tolerance and can
even be manufactured
to be flexible , showing
high elastic deformation
properties.
Industry solutions
Industrial applications for
Steps in the manufacture of CERadvance’s Duro currency

DESIGN COMPANIES AND SOFTWARE PROGRAMMES
Red Hot Manufacturing

Software! Forget next years’ Soccer World Cup, forget the economic
recession, in fact, forget pretty much everything until
you’ve seen the latest manufacturing software on the ho-
F
irst up is Version 6 (called rizon, due for release early this year. Advanced Materials
V6, don’t confuse it with Today recently had a glimpse of one of the hottest new
an engine!) of Dassault’s releases of software that promises to streamline manufac-
CATIA Product Lifecycle turing industry processes. Best of all, the new software
Management (PLM) suite. For a release is from the well-known stable of Dassault Sys-
number of years the CATIA suite tèmes (DS), a stalwart that need little if any introduction
has dominated design houses in to the local market.
the automotive and aerospace
industries, with almost all major
brands adopting the technology as a standard. The

new V6 builds on previous version’s functionality and
facilitates enhanced interactivity among users.
PLM is a set of unique business solutions that
enables an enterprise to effectively and efficiently
innovate and manage its products and related ser-
vices. This is done throughout the entire business
lifecycle, from concept through design, manufacture,
recycling and disposal.
Some contracts have already been lost

to overseas competitors as a result of
the non-compliance of software
“A lot of interest has already been shown in CATIA

V6. A major concern is South African manufactur-
ers’ comparatively slow uptake of the technology,
Igal Filipovski, managing director of CDC and we fear that if manufacturers do not comply
with OEM requirement to standardize
on a common software platform, they
will lose out on many business op-
portunities.
Contracts lost
This is particularly true in the motor
and aviation industries, where CATIA
is the de facto standard,” says Igal
Filipovski, managing director of CDC,
South African VAR (Value Added Re-
seller) for the entire DS PLM solution
portfolio.
He adds that some contracts have al-
ready been lost to overseas competitors
as a result of the non-compliance of
software used by local automotive and
aerospace suppliers. The new software,
however, has enough features and
benefits to convince the most die-hard
manufacturing companies to invest in

PLM technology. CATIA is considered to

be the most powerful and widely-used
CAD/CAM/CAE software of its kind in the
world, with over 200 different products
and configurations that can be tailored
to address essentially any manufacturing
environment. Well-known examples of
leading users include such diverse and
household names as BMW, Toyota, Airbus,
Boeing, Black and Decker, Electrolux,
Coca-Cola, Swatch, Sony, Canon, and
many more.
CATIA V6 was developed in

response to continuous
pressure from OEM’s to shorten
time to market and to reduce
costs
Igal is upbeat about the prospects the
software holds for South African busi-
nessmen. “It streamlines the complete
development process from idea to design
through the entire product lifecycle by
providing a virtual environment for testing,
prototyping and manufacturing.
Going global
It also drives the development of in-
novative, high quality products while
drastically reducing time for development,
cutting costs and providing faster return
on investment. Furthermore, it gives lo-
cal enterprises the tools to enable them
to bid, compete and win in the global
marketplace.” Simulation using 3DVIA
He says that CATIA V6 was

developed in response to
continuous pressure from
OEM’s to shorten time
to market and to reduce
costs. The latest version
was developed in close
collaboration with users,
and includes enhance-
ments that are delivered
in the three sectors of V6’s
organic architecture (Life-
like Experience, Collabora-
tive I-PLM and Intellectual
Property (IP) Creation).
This extends the reach of
the V6 platform beyond
on-premises solutions to
include mobile and cloud
solutions.
The V6 platform delivers
new and unique capa-
bilities that connect users
within their companies
or with external online The aerospace industry uses the CATIA suite of software for design and development of aircraft

communities. It enables them to create and share control required in industrial companies.
their 3D Experiences and IP with the ease-of-use
Lifelike Experience
of common Internet tools, while maintaining the
Applications such as 3DVIA Mobile deliver unique,
online 3D simulation facilities. Users
can generate realistic 3D content from
CATIA’s extensive 3D online library and
immediately enrich their visual produc-
tions such as Technical Illustration. It
enables the creation of lifelike interac-
tive scenarios on virtual products and
connects directly to 3DVIA.com com-
munities, where 3D experiences can be
easily created and stored.
CATIA V6 has major new capabilities
for systems engineering, mechatron-
ics, regulatory compliance and digital
manufacturing for high-tech Intellectual
Property creation. It now links IP creators
to collaborators, providing intuitive solu-
tions to shape, compose and repurpose
any 3D virtual product
South Africa’s very own

electric vehicle manufacturer,
Optimal Energy, will use the
system to enter into production
of its much-talked-about Joule
environmentally-friendly car
Other exciting additions to the Dassault

Systèmes suite include the new Delmia
application that enables lifelike digital
manufacturing environments to be cre-
ated, to simulate assembly sequences and
define the behaviour of any controlled
machine – CNC machines, robotics
and so forth.
Industry uptake
The Simulia product extends its unique
collaborative environment for performing
lifelike simulation and product behaviour
testing, allowing designers to perform
structural and thermal analysis on
products prior to manufacture.
French vehicle manufacturer Renault
will be the first automotive manufac-
turer to migrate to the latest version,
and South Africa’s very own electric
vehicle manufacturer, Optimal Energy,
will use the system to enter into pro-
duction of its much-talked-about Joule
environmentally-friendly car.
CDC, Igal Filipovski, Tel: (011) 786 3516,
Fax: (011) 786 3520, Email: igal@cdcza.
co.za, Web: www.cdcza.co.za

CUSTOMISING
Hot Iron, Shiny Wings and

a Highway to Heaven
Her pulse quickens, small beads of sweat glisten on her temples as flushes of ecstasy wash over her every
thought. On and on it goes tingling, tantalizing every inch of her lithe body, pushing her to the verge of plea-
sure and beyond. A strand of blonde hair whispers over her blue eyes as she bites hard on her glistening bot-
tom lip in a vein attempt to stop herself wishing, begging out loud for more. Just then the rhythmic pulsating
between her legs drives upwards shaking her to her very core and she responds by subtly tightening her long
legs around the muscular, hard frame.
S
he visualizes every detail of the beast, its
masculine form working, heaving underneath
her. Her pleasure senses are in overdrive and
the anticipated climax comes suddenly and
ferociously as a desert storm. The last powerful
thrust straightens her back and forces her to push
her bottom firmly onto the soft seat. As she slides
her rear wheel to a stop and dismounts her custom
motorcycle she is left deeply satisfied but lusting
more of the thrills that only those who have expe-
rienced riding the open rode will understand.
Whether they choose to think of their

bike as a bucking filly or sleek stallion is
entirely a matter of choice
Maybe the description of the pleasure that bikers
derive from riding their bikes is a bit over the top
and overdone, but according to those that do it on
a regular basis it is a hardcore, almost spiritual
experience to ride a bike hard and fast. Whether
they choose to think of their bike as a bucking
filly or sleek stallion is entirely a matter of choice,
although one thing is certain and that is that a
true biker will stop at nothing to perfect their ride
and make it as individual to them as is their very
own fingerprint.
Meet Louis
Louis Horn, owner of The Wrench, makes his living

CUSTOMISING
from customizing bike designs for bikers from all outcome to know whether he will get the prize and
walks of society. be able to move in to a suitably sized shop.
True to biker tradition his long hair and tatty jeans At the back, in the workshop, a number of custom-
give him a bit of a rough and ready appearance, but ized bikes are being assembled and some are ready
his looks belie a smart business brain and highly for delivery. A big all-aluminium bike catches my
skilled craftsman. When Advanced Materials Today attention and Louis is quick to point out that although
pays him a visit at his premises in Centurion, that it looks good, aluminium is a poor substitute for
doubles as both showroom and workshop, it is clear steel when it comes to building cruisers.
that business is good because there is little space Apart from difficulty in threading and seating
to move between spares, accessories, clothes and aluminium, it is not nearly as strong and rugged
bikes. The business is bursting out of it’s seams and as steel and loses its shine quickly by compari-
Louis is trying his utmost to make use of the space son. Although he himself is not a big fan of shiny
he’s got. He points to a much bigger premises over chrome and flashy metals, he would rather work
the way from his shop that is standing empty pend- with this material than aluminium or other non-
ing the outcome of a legal dispute. Some time ago ferrous metals.
he submitted the paperwork to lease the premises
from the landlord and is patiently waiting for an Trends
“The current trend is for matt finishes of steelwork
I have seen a definite shift to ‘old school’ choppers and low gloss or matt paintwork. This is almost a
rebuff of the style that was popular
over the last decade when shine and
bling bling was the order of the day.
In much the same way the ultra-
modern designs that were inspired
purely by looks were often impracti-
cal and I have seen a definite shift
to ‘old school’ choppers like those
that became popular in the nineteen
sixties and seventies.
Louis builds the majority of his bikes
from the ground up. His workshop has
all the tools and machines needed
to fabricate everything from the
mudguards to the tank and covers.
He has even started building his own
frames and if the client has specific
requirements for motors, wheels or
customised parts he has a network of
suppliers that will ensure it is made
to specifications.
Engines, transmission, brakes and
electronics are the only ‘off the shelf’
parts that are not made by his team,
although extensive customizations
can be carried out as required.
His bikes are good, damn good and
it is not by chance that Louis was
approached to build two custom
choppers with the well-known Tuttle
family from Orange County Choppers
- hosts of the American Chopper
series on TV. During their visit Louis
took part in live build-offs in front of
huge audiences to give the public
a taste of what it takes to build a
custom chopper.
Smooth as silk
On the other side of the Boerewors
curtain in the western region of Johan-

CUSTOMISING
nesburg, Tommie Roos runs a super-slick operation. But, more about the lifestyle later, we asked Tom-
Under the old banner of South Side Choppers he mie what goes into building a bike, apart from the
and his team were twice crowned as overall winners passion and money, oh yes, lots of money. Hand
in the custom bike section of the Castol Extreme built custom bikes aren’t cheap and his have a
Motor Show in 2007 and 2008. starting pricetag of around R300 000 and there is
Having sold the business early last year to take no limit to what people will fork out for their dream
over the reigns of Harley-Davidson Clearwater, he
How you define yourself and the biker lifestyle you
was eager to prove that the legend continues and
that the new operation is capable of building some choose is entirely up to you
of the country’s finest
custom bikes ever pro-
duced on home soil. Just
to drive that point home
he recently walked away
with overall top honours at
the Castol Biker Build-Off
competition with his dark
angel bike.
Wild at heart
Tommy comes across as a
wild at heart biker that has
been somewhat tamed by
the world of business. The
business dress and short-
back-and-sides haircut
cannot completely hide the
wild side, but, admittedly,
does a good job disguising
it. Like his bikes, Tommy
exudes a special kind of
passion for his job. “I love
everything about bikes and
the lifestyle that comes
with it. For our team here
at Clearwater Harley and
our customers the bike
is a passport to a whole
new lifestyle. How you
define yourself and the
biker lifestyle you choose
is entirely up to you,”
Tommie says.
“On the open road bikers
get a sense of freedom
and escape into a dif-
ferent world where all
that matter is the road,
the bike and the journey.
Pretty soon most serious
bikers develop a sense of
individuality based on their
experiences on the road,
their riding style and indi-
vidual preferences. Pretty
soon the bike becomes part
of their existence and this
leads to a need to individu-
alise their machine. That’s
where customization takes
a hold.

CUSTOMISING
machine. For this reason most of his clients are customizations may be required to individualise
from the more well-heeled folk among us. it and then, well, you can quite quickly spend a
whole lot of money, fairly quickly.
Money, money
Even those less well-heeled individuals needn’t “To build a custom you have to get into that person’s
despair because they can always buy a Harley head. Find out more about them, what makes
from him for a little less. Although some radical them tick and what their passions are. Ask lots of
From the day the concept is born to the delivery it is an questions and start piecing together who they are
and what they want.
evolution rather than a strict building project
Normally the client will give you a theme, say for
example, Batman and then you start
picking apart all the elements of the
theme and translating it to that client’s
persona. Then, only then, do you start
planning and building the bike.
“But its not as easy as that because once
you get going the bike takes on a life
of its own. Changes and improvements
and fine-tuning throughout the building
process transforms the bike to a large
extent and it can be quite different from
what you set out to build in the first
place. From the day the concept is born
to the delivery it is an evolution rather
than a strict building project.”
And he should know, he has the awards
to show for it. Tommie has used many
different materials on his bikes includ-
ing a mostly brass bike, a carbon fibre
bike and any number of different metals

CUSTOMISING
combinations. the crowd. Like its owner it is big and flashy and
Chrome and highly polished finishes are always exudes attitude. The bike is low-slung, long and
classical although new trends toward matt
paintwork and metal finishes are growing in
popularity, especially among those who have
already owned shiny chromed bikes and are
looking for something different.
Why custom
A fully customized motorbike is as much an
expression of ones personality as is your haircut
or designer clothing. In biker circles it is about
individuality and standing out among the crowd.
Generally the more extroverted the personality,
the more radical the bike. Although, in some
instances the bike may be an expression of the
inner-personality rather than the person that
society has moulded.
A good example of a bike that was built to
fit the personality is that of Clint Aspeling, a
well-known West Rand restaurateur and self-
confessed limelight junkie. His bike fits the
larger than life attitude that sets Clint apart in

CUSTOMISING
while a growing number

of people choose to buy
an off-the-shelf motorbike
and customize it to their
own taste. This type of
customization is usually
reserved for those that like
to stand out in a crowd,
but value the comfort,
reliability and availability
of parts that is afforded
when buying ‘big brand’
motorbikes. Customisation
is less radical and usually
goes as far as paintwork,
accessories and wheels. Al-
though less exclusive they
are nonetheless individual
and beautiful in their own
‘mass produced’ way.
Lifestyle
Clint Aspeling Unlike the superbike bri-
gade, riders of cruisers
aggressive and by Clint’s own admission is better to
don’t get their thrills from outright speed alone.
look at than to ride. In order to get the look right,
The average cruiser rider is looking for ease of rid-
the rider has to do some fancy maneuvering to reach
ing that doesn’t entail hairing up and down gears
the handlebars, get the feet to the pedals and stay
through a close ratio gearbox.
in control of the beast with its massive 2.5 litre
engine doing its utmost to shake its mount. It is more about setting the throttle and using
the large capacity motor’s brut power or torque
Price was not an option and the final price tag amounted
to power up and down hills or mountains with
to more than half-a-million Rand minimum fuss. Power is usually delivered through
a large capacity motor that gushes torque in a
“If I wanted a comfortable bike for the long road I
flat curve from low revs all the way through to its
would have bought a Harley. This isn’t about speed
red line. The ear-popping sound is as individual
or comfort or anything else, it’s about being noticed.
as the bike and in some instances it seems the
The bike is loud and its mean and pulls a crowd
louder the bike, the better. In fact, when it comes
wherever it goes - that’s what I bought – being the
to custom bikes the sound is as important as any
focus of attention.
other tailor-made part.
Crowd puller Whether cruising hundreds of kilometers on a
Kids love it and want to sit on it, men admire it customized Harley Davidson or Gold Wing, or
and chicks dig it,” Clint laughs. cruising from News Café to News Café to show off
Clint is one of a breed of wealthy men and woman your stead and feed the ‘old ego’, the one thing
that are prepared to pay top Dollar for handmade riders have in common is the freedom of the road.
unique bikes built to their standards to suite them. The element of danger and not conforming to the
The award winning bike that Clint dreamed-up was norm brings a sense of camaraderie and often leads
built from the ground up by Tommy and his team to strong bonds developing between people from
and took months to complete. Certain parts had to different walks of life.
be specially made and imported from the United This same sense of camaraderie cuts across classes
States, while others were hand crafted locally. and on the road all bikers are just that – bikers.
Everything about the bike is handcrafted from the In the case of a custom bike rider its all the same,
leather hand stitched, etched and custom-fit seat just the size, colour, height, wheels, graphics (and
to the metal work and trimmings that were either everything else) that counts.
fabricated by the shop or outsourced to fabrication The Wrench, Louis Horne, Tel / Fax: (012) 663 5059, Email:
plants around the country. The paintwork and de- thewrench@acenet.co.za, Web: www.the-wrench.com.
tailing that was carried out by a local specialist is Harley-Davidson Clearwater, Tommie Roos, Tel: (011) 675
a work-of-art and equally as original as the bike. 5443, Fax: (011) 675 5443, Email: tommie@clearwaterhd.
Price was not an option and the final price tag co.za, Web: www.harley-clearwater.co.za
amounted to more than half-a-million Rand.
Others choose less radical custom-built bikes,

International News
control system had become increasingly
unreliable, resulting in high maintenance
overhead and unacceptable downtime.
The machine’s new NUM CNC software
includes the NUMGear package, which
features a highly intuitive graphical user
interface to help maximise productivity.
This software also performs all of the
functions, which previously required
an external electronic gearbox, thereby
reducing the complexity of the system
and the number of parts that require
maintenance.
Gleason Corporation is a world leader
in gearing technology. The Gleason 782
gear hobber is widely regarded as an
industrial workhorse, it enjoys a very
large customer base. However, this
particular machine’s control system
was showing signs of age. In this case,
the gear hobber has seven CNC axes,
which were controlled by an Allen Brad-
ley 8600 CNC system and an external
Multi-Seals new dissolvable spacers electronic gearbox, both of which had
become outdated, unreliable and difficult
Wash-away spacers
Multi-Seals has introduced a range of Wash-Away
dissolvable spacers, designed to provide consistent
spacing between printed circuit boards and PCB
components.
These organic polymer spacers locate PCB components
during soldering operations. After soldering, Wash-
Aways dissolve in water or alcohol baths. This leaves
uniform spacing between components and boards,
which provides free circulation of air, mechanical
protection, optimum filleting, and greater accessibility
for inspection, cleaning, and conformal coating.
Wash-Aways are available in a wide range of sizes
and shapes to accommodate a variety of PCB com-
ponents, including resistors, capacitors, transistors,
potentiometers, and integrated circuits. Wash-Aways
contain no ionizable material, salts, sugars, metals,
or soaps, and they are non-corrosive, non-conductive,
and non-toxic.
Multi-Seals, Email: sales@multi-seals.com, Web: www.
multi-seals.com
Hobber restored
Automation upgrade specialists MasterControls and
Southern Technical Services have jointly retrofitted
a Gleason 782 gear hobber with a new CNC control
system from NUM. The machine is used by a large
aerospace components manufacturer in Chihuahua,
Mexico, to produce spur, helical and crown gears with An internal view of the gear hobber, showing the complex multi-axis system and
complex profiles. Prior to the retrofit, the machine’s the hob shaft

International News
to maintain. After several months of intermittent operation, Super precision machining center
the company solicited the help of MCI and STS to restore Today’s aerospace companies are faced with the demands
the machine to peak operational condition at a fraction of of machining exotic materials and hard-to-machine charac-
the cost of a new machine. teristics such as titanium and Inconel. These manufacturing
MasterControls Inc. (MCI) and Southern Technical Services challenges are further compounded when precision bores and
(STS) quickly ascertained that the gear hobber was in excel- dimensional shapes require machined tolerances in the single
lent mechanical condition, but would benefit from new CNC micron range. For this reason StarragHeckert has introduced
control hardware and software, together with a new operator’s the SIP SPC (Super Precision Center) Series specifically built
panel and some associated control modules. The customer to meet these demanding applications.
requested that the machine’s existing drives, motors and
feedback devices – all of which were perfectly serviceable
– should be retained, and also stipulated that the machine
footprint should not be changed. MCI and STS accommodated
this latter demand by developing an entirely new sub-panel
containing the new NUM CNC, power supplies, circuit break-
ers and contactors, which was subsequently mounted inside
the machine’s existing control cabinet.
The retrofit package is based entirely on NUM equipment.
As well as the new seven-axis CNC controller, this includes a
new PC based operator’s panel, which features a large, easy-
to-read 15-inch LCD screen with a full membrane keyboard,
and a 61-button machine tool builder’s panel with a hand
pulse generator. An industrial mouse was also mounted on
the operator panel, for convenience of the operator.
NUM (UK) Ltd, Email: sales.uk@num.com, Web: www.num.com
a-
m r-
o n ta
c isi m S
e
pr fro
r
i gh nte
h e
w c t
ne g er
A inin eck
ch gh
ra
The proven high precision machine design and geometry

works in tandem with the machine’s high productivity features
delivering substantial benefits. The result is that for the first
time precision parts can be produced in volume at standards
of super accuracy as yet unattainable within a production
environment. The SPC 7120 and 7140 SIP horizontal
machining centers (HMC) feature a compact design, highly
productive tool and workpiece handling and are ideally suited
for a broad spectrum of production applications — while
routinely achieving 4µ precision and accuracy (according to
VDI/DGQ 3441). The SPC has selectable process adaptation
parameters automatically optimising machine performance
depending on roughing, finishing and fine finishing opera-
tion requirements.
The SPC SIP is equipped with either the Siemens 840 D or
Fanuc 31i CNC control system.
The SPC 7120 SIP’s travel values are 1,200 mm in X, 950
mm in Y and 1,200 mm in Z. (7140: 1450 mm in X, 1100
mm in Y and 1300 in Z.) Working feed rates are 40 m/min
(X, Y and Z), while rapid traverse rates are 40 m/min in all
three axes. Rapid traverse rate of the B-axis is 25 U/min.
Acceleration rates are 3.5 m/sec2 in X, Y and Z axes. Ac-
curacy of linear axes: positioning deviation of <0.004 mm;
repeatability of <0.002 mm and maximum backlash width
U max of <0.001 mm.
Starragheckert, Jean-Daniel Isoz, Email: jdisoz@starragheckert.
com

International News
Count on platinum million ounces in China alone.
Global net jewellery demand for platinum is expected to Europe
climb by almost eighty per cent to 2.45 million ounces this Purchases of platinum by the European jewellery and watch
year according to Johnson Matthey’s “Platinum 2009 Interim industries are forecast to decrease by 15,000 oz to an esti-
Review”, released in November last year. Net demand will mated 185,000 oz this year. The European luxury jewellery
fall in Europe and North America, reflecting tough economic manufacturers have struggled with the effects of the financial
conditions. However, in Japan, lower prices have reduced crisis and demand will fall as a result. However, demand
recycling flows and, although manufacturing levels will rise for platinum in the key UK market has been supported by
only slightly from 2008, net demand will climb strongly. In a robust bridal market and platinum demand is likely to be
China, the metal price has continued to encourage demand steady year-on-year. Platinum use in the Swiss watch industry
from the jewellery sector, which should leap to a record level will drop due to lower watch production and careful stock
of 1.75 million ounces in 2009 due to strong consumer control by manufacturers and retailers.
purchasing and hefty restocking throughout the industry.
Japan
Net Japanese platinum jewellery demand is expected
to climb by 255,000 oz to 310,000 oz in 2009.
The lower metal price has reduced the incentive for
consumers to cash in second hand jewellery and the
rate of recycling of jewellery scrap will therefore fall
sharply. Gross demand (equivalent to manufacturing
volumes and any changes in industry stock levels) rose
by 10,000 oz to 540,000 oz as retailers who reduced
their prices saw improved sales of platinum jewellery.
Production of platinum chain for sale in Japan and
for export to China also increased.
North America
The jewellery market in North America has struggled
in worsening economic conditions. Net platinum
demand is forecast to fall by more than a quarter
this year to 140,000 oz as consumers’ disposable
income has shrunk and retailers have again reduced
working stocks.
Platinum 2009 Interim Review is Johnson Matthey’s latest
market survey of platinum group metals supply and demand.
This report, widely regarded as the world’s principal source
of information on platinum group metals, is free of charge. It
can be viewed and downloaded as an electronic file or can be
ordered in printed form from Johnson Matthey at http://www.
platinum.matthey.com/publications/pgmreview.html
China Engineer Placements

The lower price of platinum compared to the first half of
2008 has had a hugely positive effect on net Chinese jew- Our job board continues to display a wide variety
ellery demand which is expected to rise to a record 1.75 of excellent job positions that you can review and
million ounces this year. Lower prices provided retailers and apply for on-line. Keep your credentials on our
wholesalers with the opportunity to replenish and expand
secure and confidential database.
stocks, increasing platinum’s share of counter space where
it replaced white gold jewellery. Attractive profit margins also
encouraged new retailers and new manufacturers into this We include the projects for: Eskom,
sector. This widespread restocking drove a dizzying increase Gautrain, PBMR, The SA Oil and Gas
in demand in the first half of 2009 in particular. Continued expansion, and International options.:
economic growth and a fall in the retail price of platinum
jewellery also considerably boosted the weight of platinum Login to
sold through to consumers. Together, these trends increased www.engineerplacements.com
net platinum demand in the first half of 2009 to over one

Industry News
Apprentice grooming
Steps are being taken by one of the
country’s leading engine and propulsion
system suppliers to address the shortage
of suitably qualified artisans and engineers
in the technical fields, especially in the
Marine Diesel Fitter Trade.
MTU South Africa is embarking on a
training program to develop the skills
of artisans for diesel engine repairs and
maintenance fields. The company has
accreditation as a training establishment
from the manufacturing, engineering and
related services SETA (merSETA).
“The goal is to re-introduce highly-skilled
and qualified tradesmen that are ready to
be employed by local and international
MTU associated companies. MTU SA also
aims at producing sought-after artisans
that are instantly recognisable as MTU
trainees,” says Michael Baumann, Manag-
ing Director of MTU South Africa.
A number of apprentices are receiving hands-on training at MTU South Africa
Starting as an apprentice with MTU SA,
the trainee will receive training and coaching by qualified ing at Further Education and Training colleges (FET) and by
artisans. The training entails practical learning conducted accredited training providers in SA. A dedicated “Apprentice
in the company’s workshops based in Cape Town, Simon’s Trainer” has been appointed to train, guide, coach and moni-
Town and Johannesburg as well as relevant theoretical train- tor the development and progress of the trainees.
The company currently has nine apprentices in their training
program, with five of them awaiting dates from the Artisan
Testing Centers for their final practical exam to qualify as
artisans. It is envisaged that MTU SA will have a further intake
of five apprentices in 2010 and five every year thereafter
until a total of 20 trainees in the program is achieved.
MTU South Africa, Michael Baumann, Tel: (021) 529 5760, Fax:
(021) 551 1970, Email: info@mtu-online.co.za, Web: www.mtu-
online.co.za
New Structural Tube Steel Launched

The Association of Steel Tube and Pipe Manufacturers of
South Africa (ASTPM) and the Southern African Institute
of Steel Construction (SAISC) are launching a new grade of
S355 steel for structural tube. The new grade, which re-
places the previous 300 standard, has been designed using
international best practice and complies with the minimum
standard based on EN10219 Part 1.
“This will make a significant difference to the structural steel
tube industry as, for the same amount of steel as the previ-
ous 300 standard, higher loads can now be resisted,” says
ASTPM executive director Colin Shaw. “This will render steel
tube much more competitive against both other steel profiles
and other construction methods like reinforced concrete.”
SAISC executive director, Dr Hennie de Clercq, says that

Industry News
Factors taken into accounts during the
design and engineering phases of these
particular chutes have included height
of transfer drop, throughput rates and
tonnages as well as maximum lump
size. “Furthermore, operational data
from the first installations was carefully
analysed to ensure that the chutes for
KEP would incorporate modifications
and enhancements to mitigate against
material properties thereby facilitating
the efficient transfer of material,” Crui-
kshank adds.
Cruikshank says that a particular chute
being supplied which will clearly showcase
Weba Chute System’s design capability
and the company’s intimate understand-
ing of material and transfer points will
be installed in the off-grade washing and
screening plant. This chute has been
designed to facilitate a proportional split
which will allow the material to be split
proportionally between two different
S355 will help considerably in the process of encouraging outgoing conveyors.
architects and engineers to, build high-rise structures in
“This is not the same as a bifurcating chute which the company
steel rather than concrete. “We will be promoting strongly
the advantages of tubular steel and steel in general for these
structures,” says de Clercq.
ASTPM’s Technical Committee chairman, Franco Mordini says
apart from its widely acclaimed aesthetic properties, it is
becoming increasingly accepted that closed tubular sections,
when concentrically loaded in compression, offer consider-
able savings to structures. Also, tube is inherently the most
efficient form for resisting torsion loads, which may also be
applied during the fabrication and erection processes.
SAISC, Hennie de Clercq, Tel: (011) 726.6111, Fax: (011) 482.9644,
EMail: info@saisc.co.za
Chutes for KEP

Weba Chutes Systems are being supplied to the Khumani
Expansion Project for both the King Project and the Parsons/
Brownfields Project. The Khumani Mine is part of Assmang
Limited which is jointly owned and controlled by African
Rainbow Minerals Limited and Assore Limited.
Ted Cruickshank, drawing office manager, at Weba Chute
Systems says the majority of the chutes will be similar, if
not identical, to those chutes which were manufactured for
the first phase the Khumani Expansion Project. “Iron ore
is known for its high wear characteristics and is extremely
abrasive. Weba Chute Systems has an established reference
within the iron ore sector for its engineering design which
takes the high rate of wear into account, and our innovative
design where material runs on material goes a long way to
mitigating against,” Cruikshank says.
A diagram of the primary crusher apron feeder discharge chute

Industry News
often uses as a solution where a 50/50 split is required,” he
says. “In this particular case, the split will vary depending
on the actual plant requirements and the chute has been Subscription
engineered in such a manner so as to allow the split to be
automatically adjusted as and when necessary.” Please fax us if you wish to subscribe to “Advanced Materials Today”
M&J Engineering, Mark Baller, Tel: (011) 827 9372, Fax: (011) 827 at R375,00 (incl postage and VAT) per year; R875,00 per year for Af-
6132, Web: www.weba.co.za rica/Overseas. We will post you an invoice on receipt of your fax.
PROMECH PUBLISHING Fax No: (011) 781-1403
From:.........................................................................................
(insert your name)

Powering the future
Progress is being made to develop and manufacture mate- Title: ..........................................................................................
rials, components and systems, based on fuel cell science
and technology in South Africa, but a need for collaboration Company: .................................................................................
exists between stakeholders and industrial partners.
The observation was made Address: ..................................................................................
by Dr Oystein Ulleberg, an
internationally renowned ....................................................................................................
Norwegian scientist, who
heads up the Centre for ......................................................................Code: ..................
Systems Integration and
Technology Validation at Telephone: ( ) ....................................................................
Hydrogen South Africa
(HySA) Systems at a Fax: ( ) .................................................................................
seminar hosted by HySA
in Cape Town recently. Email:........................................................................................
“The seminar was well
attended by academics,
industry leaders as well
Dr Oystein Ulleberg of Hydrogen South as participants from the
Africa
manufacturing sector,
Index to Advertisers
who are an important Advance Net 20
part of the future success of component manufacture for
the export market. The main objective of the seminar was Africa Machine Tools 18
to get South African industry and businesses interested
AFSA Inside Back Cover
and aware of opportunities in the field of hydrogen and fuel
cells,” Oystein says. Afzelia Outside Back Cover
Opportunities include the manufacturing of materials and Anicic 15
components for hydrogen and Proton Exchange Membrane
(PEM) fuel technologies, including Lithium-ion batteries for Associated Marine 16
hybridisation. Other applications of hydrogen and fuel cell
technologies exist in near-term niche markets, with focus
Belgravium 6
on uninterrupted power systems (UPS) for telecom and CerAdvance 31
utility vehicles.
Efamatic 36
HySA Systems is part of a 15 year research, development
and innovation programme on hydrogen and fuel cell technol- Engineer Placements 35
ogy, sponsored by the Department of Science and Technol-
ogy (DST) in South Africa. Oysetein adds that South Africa KEW Outside Front Cover
has great potential to manufacture various components in ILS Inside Front Cover
the hydrogen and fuel cell technology product chain. “We
are keen to engage with businesses in the manufacturing Offix Office 17
industry, especially SMEs, who are interested in finding out
Opticore 11
more about possible involvement in the future development
of HFCT. Rely IntraCast 34
Hydrogen South Africa, Dr Oystein Ulleberg, Tel: (021) 959-9319
Tomrod 19

34
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Advanced Materials Today Jan/Feb 2010 

 Advanced Materials Today Jan/Feb 2010

Advanced Materials Today Jan/Feb 2010 

KEW Foundries – Casting

 Advanced Materials Today Jan/Feb 2010

ultrasonic testing methods – to ensure that clients

KEW Foundries is making innovations

At KEW Foundries’ manufacturing facility, quality,

KEW Foundries’ sheave

Advanced Materials Today Jan/Feb 2010 

sheave wheels feature a bolted assembly which

Advanced Materials Today Jan/Feb 2010 

Ready to Steel Market

Kulungile Metals Group (KMG) CEO, Sampie

 Advanced Materials Today Jan/Feb 2010

Advanced Materials Today Jan/Feb 2010 

Pimp my CNC Machine

10 Advanced Materials Today Jan/Feb 2010

ure you are building a machine that may fail sooner

Refurbishment makes sense in current

The same highly-skilled team of engineers that con-

Advanced Materials Today Jan/Feb 2010 11

We went from running double shifts to laying off 28

battering and orders for parts for the mining and

12 Advanced Materials Today Jan/Feb 2010

Advanced Materials Today Jan/Feb 2010 13

Raw Energy Drives

Parts and pressure parts for the new power stations

14 Advanced Materials Today Jan/Feb 2010

A ceramic header pipe

In turn, thousands of kilometers of specialized welds

The main workshop is some 800 m long to

Advanced Materials Today Jan/Feb 2010 15

More than 5% of the

South African footprint

16 Advanced Materials Today Jan/Feb 2010

Heart of the company

Advanced Materials Today Jan/Feb 2010 17

class organisation that sets high standards

Expansion into other projects on

18 Advanced Materials Today Jan/Feb 2010

Soon to be commissioned induction bending machine

Advanced Materials Today Jan/Feb 2010 19

the cards, where its expertise in the

Steinmüller’s local power milestones

that swift, on time delivery is the order of the day

20 Advanced Materials Today Jan/Feb 2010

Ancient Wonder Material

bathroom ware in house-

Advanced Materials Today Jan/Feb 2010 21

talline design principles are adhered to, they are

22 Advanced Materials Today Jan/Feb 2010

the strong and du-

Advanced Materials Today Jan/Feb 2010 23

Red Hot Manufacturing

brands adopting the technology as a standard. The

Some contracts have already been lost

“A lot of interest has already been shown in CATIA

24 Advanced Materials Today Jan/Feb 2010

PLM technology. CATIA is considered to

CATIA V6 was developed in

He says that CATIA V6 was

Advanced Materials Today Jan/Feb 2010 25

South Africa’s very own

Advanced Materials Today Jan/Feb 2010

Advanced Materials Today Jan/Feb 2010

Advanced Materials Today Jan/Feb 2010

Advanced Materials Today Jan/Feb 2010

Advanced Materials Today Jan/Feb 2010

Advanced Materials Today Jan/Feb 2010

Advanced Materials Today Jan/Feb 2010

Advanced Materials Today Jan/Feb 2010