TSF Decant System Outfall Pipes Sealing Project

TSF Decant System Outfall Pipes Sealing Project

Foskor (Pty) Ltd

Phalaborwa, South Africa

  • Successful sealing of four outfall pipes and one decant inlet
  • No operational downtime
  • Implementation of innovative cost saving construction methods
  • Stakeholder involvement
  • Ability to become an extension of the client’s team
  • Ability to swiftly respond to site conditions and risks 
  • On time and within budget project completion
Project Overview

Knight Piésold was appointed as the EPC contractor to undertake the South tailings storage facility (TSF) and Selati TSF old outfall pipes and decant tower sealing project. With a storage capacity of 324 million m3 and a footprint of 1,100 hectares, the Selati TSF is one of the larger structures in Africa. Knight Piésold sub-contracted a specialist geotechnical drilling contractor. For the ad-hoc civil, earthworks, mechanical and support services, competent local contractors and suppliers were used. The excellent safety record on the project was a significant achievement as the work consisted of precision drilling, deep excavations in unstable material, high water pressure in outfall pipes, and open water construction activities.

Project Role

Knight Piésold was appointed by Foskor as the main contractor to execute the project. The appointment implied that Knight Piésold had to take full responsibility for a turnkey ‘Design and Construct’ solution. Because of the high potential of risk involved with dam decant sealing work, Knight Piésold had done a thorough constructability review and risk assessment before a high-risk task was implemented. Quality control always received a high priority on the project and was closely managed by using Knight Piésold’s quality management system, data management system (FULCRUM), and field procedures for construction projects.

The main roles undertaken included:

  • Detail design and engineering
  • Procurement management
  • Construction management
  • Mine health and safety management
  • QC/QA management
  • Site supervision
  • Contract management
  • Risk management
  • Dams operations staff interaction and planning