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A Stefanutti Stocks Publication

Continuous pursuit of higher levels of performance

Remote Mining Infrastructure


Excelling in Safety


Constructing Malls in Africa


Bridge Rehabilitation


Piling for Gautrain Station


Investing in SA's Youth


A Stefanutti Stocks Publication

From the CEO


Capabilities/Industries in this volume:


Stefanutti Stocks Civils Stefanutti Stocks Mechanical


As 2010 draws to a close one can look back on the year with mixed feelings. The world economy is still trying to regain confidence after the financial markets' crash late in 2008. Government's promised infrastructure roll-out has not yet materialised, there has been limited spend on surface infrastructure from mining houses and the funding of projects has proven problematic. On the positive side, the interest rate is at its lowest in years and South Africa hosted a very successful Soccer World Cup, which benefited local construction companies. Despite the market slump during the year, we have recently seen some encouraging signs of recovery. Although our headline earnings per share for the six months to August 2010 was down by 14%, in that same period our order book grew by 10% and is currently sitting at R6.8 billion. In addition there are some promising opportunities still on the horizon. The Structures Business Unit has been awarded numerous projects in the mining infrastructure field including two R300 million apiece projects at Grootegeluk Mine in the Limpopo Province, as well as projects further afield in Sierra Leone and Namibia. The past few months has also seen our Buildings Business Unit expand our presence in Africa with new projects in Botswana, Malawi and Mozambique. Growth into Africa is high on our agenda, especially in light of the fact that approximately 30% of the Group's total operating profit for the interim period has been generated there.

Mining - Infrastructure

Stefanutti Stocks Civils Stefanutti Stocks Mining Services Stefanutti Stocks Roads & Earthworks




Transport Nodes & Infrastructure

Stefanutti Stocks Civils Stefanutti Stocks Civils KZN Stefanutti Stocks Geotechnical Stefanutti Stocks Roads & Earthworks


Stefanutti Stocks Civils KZN Stefanutti Stocks Power Stefanutti Stocks Civils



Stefanutti Stocks Civils KZN



Building Construction

Stefanutti Stocks Geotechnical Stefanutti Stocks Building Business Unit


Safety / Awards Socio Economic Development Social

22-24 25-26 27


Our passion and unwavering commitment to service excellence continually surpasses each benchmark we set, and will continue to drive the success of the Stefanutti Stocks Group. Stefanutti Stocks Holdings Limited | Tel: +27 11 571 4300 | We would like to thank all contributors, both editorial and photographic. Front cover photographs, from top to bottom, left to right: 1. Thubelisha Twistdraai Collery, Secunda (page 6). 2. Liberty Life (page 24). 3. Mining Services (page 7). Comments & contributions | [email protected] Compiled on behalf of Stefanutti Stocks by Gerbera Brand Management | Cell +27 82 371 1005

PAGE 1 | Benchmark

What's New?

Appointments and


Stefanutti Stocks Holdings

The acquisition of Apollo E&I Construction (Pty) Ltd has enhanced our Mechanical, Electrical and Power Business Unit, broadening our capability in the expanding electrical and instrumentation field. Although our Mining Services Business Unit experienced some setbacks during the year with contract cancellation and delayed awards, we are now expecting a number of awards to come to fruition, this is expected to provide a meaningful contribution to the Group's top and bottom line growth. Our stringent commitment to improving our safety standards is paying dividends. The Group's Disabling Injury Frequency Rate (DIFR) is down to 0.29 - and we have won numerous safety awards. I want to make use of this opportunity to congratulate our teams on this outstanding performance and in making our working areas a safe place to be. Market indications are that the construction sector will remain under pressure over the next 12-18 months. However, in light of the developments we have seen in recent months, we are cautiously optimistic on the short- to medium-term outlook. We intend to use this period to continue with our committed training programme and to position ourselves for the next expected upswing. On behalf of the board of directors, and our management teams at Stefanutti Stocks, I would like to commend and thank you for your efforts during 2010. We all wish you and your families a blessed, peaceful and joyous festive season and look forward to g g gear. kicking off 2011 in high g · Stephen Pell: (Pictured right) COO (chief operating officer)

Mechanical, Electrical & Power Business Unit

· Daryl Barske: managing director (Electrical and Instrumentation). · Leo Verloop: technical director (Electrical and Instrumentation). · Stephen Phakasi: managing director (Power).

Roads and Earthworks

· Frik Venter: managing director (Roads and Earthworks Business Unit). · Richard Harrison: contracts director (Roads and Earthworks).

Structures Business Unit

· Geoff Thompson: business development director (Structures & MEP). · Ken Gibbs: general manager (Civils, KZN). · Brian McDonald: contracts director (Marine).

Building Business Unit

· Luc Jacobs: managing director (Building Business Unit). · Brad Wantenaar: managing director (Building Gauteng). · Lee Cochrane: financial director (Building Africa).

Stefanutti Stocks Middle East

· Casper Steenkamp: director (Dubai).

Acquisition increases Stefanutti Stocks Electrical & Instrumentation

fields of electrical and instrumentation construction across South Africa and Southern Africa including Botswana, Namibia and Angola. The company has a history of delivering projects of high quality, on time and within budget without compromising on safety standards. This is reflected not only in the ISO 9001 accreditation and five star NOSA rating, but also in their impressive client portfolio, which includes BHP, SASOL, Kumba, Fluor, Anglo American and Krupp to name a few. "We are pleased to be in the Stefanutti Stocks fold and are looking forward to new growth opportunities, including increasing our South African market share as well as our footprint across Southern Africa," says Daryl Barske, managing director of Apollo.

(E&I) skills base

Source: Jan Oberholzer

In March 2010 Apollo E&I Construction (Pty) Ltd became a wholly owned subsidiary of Stefanutti Stocks, complementing and strengthening the existing E&I skills in the Group. Since it's inception in 1995, Apollo has grown into a reputable force in the



The Stefanutti Stocks Group has received numerous awards in recognition of their commitment to safety.

NOSA 5 Star: Stefanutti Stocks Civils Stefanutti Stocks Roads & Earthworks MBA 5 Star: Stefanutti Stocks Building Gauteng Stefanutti Stocks Building KZN Details on page 22-24.

PAGE 2 | Benchmark


Porto Amboim rehabilitating and upgrading a

awarded Phase 2 of the project, consisting of the control, laboratory, administration and canteen buildings, the guardhouse, ablutions, truck stop and visitor parking. Phase 3, encompassing the workshop/ warehouse, V-drains, kerbing and main road guardhouse was recently also awarded to Stefanutti Stocks. This project has benefited many individuals from the local community, with over 300 individuals receiving training in the respective construction field - skills that will stand them in good stead for future work opportunities. "Our petrochemical capabilities and wealth of experience in this industry have contributed to our success on this project," says Shaun Butler, contracts director for Stefanutti Stocks Civils. "The project has achieved 3.78 million man hours and 410 days without a lost time incident. Our people in Angola have grown into a formidable team, with a fantastic track record of delivering quality and maintaining high safety standards." Phase 3 of the project is due for completion in March 2011.

fuel storage depot

Source: Shaun Butler

For the past four years Stefanutti Stocks Civils has been working on several phases of the rehabilitation and upgrade of the fuel storage depot at the fuel terminal in Porto Amboim in Angola. The first phase,which commenced in 2007 and was completed in 2009, consisted of: · General site preparation; · New tank foundations; · Separator; · Slops tank; · Building & structures; · Road truck filling facilities; · Road loading pump bay; · Ship receiving manifold and loading bay; · Bund walls; · Drainage system; · Water supply to new offices; · Sewer system; · Paving in tank bund area; · Extension of perimeter wall; · Repair of concrete hard stand; · Extension of fire access road; · Pipe culverts; and · Pipe supports and trenches. Due to the successful completion of the first phase, Stefanutti Stocks Civils was

Construction of a petrochemical

company achieving its 5 Star NOSA rating at the end of 2009. The Stefanutti Stocks Civil small works division recently completed work on an extension of this project for Foster Wheeler, the construction of the 4th Train Landlord Substation at Secunda. The scope of work included excavations and the construction of a terrace, construction of Loffelstein retaining walls with drainage, construction of the substation and its services, and a concrete ceiling with IBR flashing for the roof. "The tight tolerances on the unistruts and epoxy floors required meticulous attention to detail," said Quentin Clark,

substation in Secunda

Source: Quentin Clark

Stefanutti Stocks Civils teams have worked at Secunda on numerous petrochemical projects in recent years. This includes the electrical and civil works for the 4th Train Landlord Project - a project that was instrumental in the

site agent for Stefanutti Stocks Civils. "The unistruts in the substation were put in within a tolerance of 1mm/1m and the epoxy floor within 3mm/20m. Our team constructed the substation to the satisfaction of our client and we are looking forward to the next challenge!" Skills development for the construction team included courses on HIRA, legal liability and incident investigation for the supervisors. Training for the workforce focused on interaction with the work environment and safety training including working at heights; working with compactors, power tools and pneumatic tools; first aid and fire training.

PAGE 3 | Benchmark


Firewater pipeline for

OR Tambo

Source: Kaare Mason

Stefanutti Stocks Civils and Stefanutti Stocks Mechanical combined forces to work on the civils, mechanical, piping and structural steel components of the OR Tambo Fire Water Pipeline contract around the Jet A1 fuel storage facility. The scope of work on this project for client ACSA included the new fire water ring main around Jet A1 storage tanks -1km of trenching, 450m HDPE piping, 57 valve chambers, steel piping and pipe support foundations. The works design had not been completed prior to the award of the tender, and the design process continued as construction progressed, resulting in numerous modifications and changes to cast in stone due to the up and coming World Cup, the mechanical site team led by Sydney Waddell, achieved the impossible by completing the bulk of the work on time. The Jet A1 fuel storage facility had very strict safety procedures in place. "This, combined with congestion on site due to seven additional contractors working in the same area, meant our teams had to be acutely aware and respectful of the surrounding environment," said Shaun Alcock, contracts director for Stefanutti Stocks Mechanical. The project was completed at the end of August 2010.

Cooling water & foam proportioner steel pipelines.

the original project plan. In addition, incessant rain, flooding and collapsing soil resulted in 70% of the excavations being done by hand. "This manual route translated into 3 500m3 of hand excavated trenches, 1.8m deep," says Kaare Mason, contracts manager for Stefanutti Stocks Civils. "Although more time consuming and labour intensive, this method was ultimately more beneficial to our client, as it also enabled easier avoidance of the buried services, many of which we were not aware of."

Excavated trench prior to collapsing.

Due to the piping scope greatly increasing (4-fold) and the completion dates being selected sub-grade layers and a cement stabilised sub-base layer topped with a 300mm thick 4.8Mpa flexural strength unreinforced slab. The installation of the new Jet A1 fuel line involved the construction of four new valve chambers, the installation of 150mm steel fuel pipe with Denso wrapping for corrosion protection and four new hydrant pit valve boxes extending 30m onto the apron. "The installation of the fuel line took place within the normal operations of the airport, and we had to accommodate both aircraft and passenger traffic," said Leon van der Merwe, contracts manager for Stefanutti Stocks Civils. "Our work was done in strict accordance with the international civil aviation authority regulations and guidelines, and our team were focused on safe operations throughout." Particular attention was required for the welding procedures with non-destructive

Mathews Sehole and Walter Manyathi "maak vas".

Apron reconfiguration and fuel-line upgrade at

Bloemfontein Airport

Source: Leon van der Merwe

Stefanutti Stocks Civils was at the Bloemfontein Airport from January to June 2010, reconfiguring the existing apron to accommodate one additional bay, and to upgrade the fuel line to the four reconfigured bays. The project was one of numerous projects the Stefanutti Stocks Group have been involved in for Airports Company South Africa (ACSA), in the build up to the World Cup. The existing apron was widened by means of layer works consisting of

testing and 100% radiography testing required on all welds. On completion of welding, the entire line was purged with Nitrogen and a 36 hour pressure test was carried out. There was a two-day window to link the new system to the old system and have it fully functional in time to accommodate additional air traffic during the World Cup. The project was completed on schedule, five days before kick-off in the first match of the football event.

PAGE 4 | Benchmark

Mining - Infrastructure

Mining Infrastructure for the

Trekkopje Mine, Namibia

Source: Bob Fordyce

Namib Desert, where daytime temperatures can reach 50°C. Water for the project is supplied from a desalination plant located between Swakopmund and Henties Bay. The site establishment will be completed by the end of October and includes a ready mix concrete batching plant and site offices. Services include a voice over IP for telecommunications and a wimax link into the Stefanutti Stocks MPLS network at the Kempton Park head office in South Africa. The nearby village of Arandis is a hive of activity with recruitment of local employees and skills training taking priority. "We have to date screened 260 individuals in Arandis," says Bob Fordyce, Stefanutti Stocks Civils contracts director. "Currently 31 concrete hands, 30 shutter hands, 30 scaffold erectors and 70 general labourers are going through our training facility where they will receive formal training which is certified by both CETA and the local NIMT.* The training facility is run in a collaborative effort between the NIMT and the Stefanutti Stocks Civils Training Centre. The project is subject to a very tight programme, with completion scheduled for mid 2011. Fanie van Tonder, the project manager from Stefanutti Stocks Civils leads a motivated and skilled team on behalf of the Joint Venture. Quantities: · Concrete: 39 000m3 · Formwork: 45 000m2 · Reinforcing: 3 350ton · Brickwork: 5 000 m2

* CETA - Construction Education and Training Authority. * NIMT - Namibia Institute of Mining and Technology.

AREVA Processing Namibia (Proprietary) Limited awarded the Stefanutti Stocks/ Namibia Construction Joint Venture with the Trekkopje Maxi Project Front End Civil Works project, which commenced in August 2010. The scope of civil structures work comprises of: · 12km concrete rail beams; · A crushing and screening plant: · An agglomeration plant; · Two silos; · A number of large in-situ culverts; · Conveyor lines; and · Miscellaneous civil works and associated industrial building works. The Trekkopje Mine project site is located 125km from Swakopmund, in the

PAGE 5 | Benchmark

Pictured here and on the right: New recruits to the training facility undergo practical and theoretical training.

Mining - Infrastructure

Infrastructure for the

A coal bunker and overland conveyors mining infrastructure for the Twistdraai

Tonkolili Mine in Sierra Leone

Source: Shaun Butler

Sierra Leone, a country rich in raw materials, is aspiring to become one of the world's leading iron ore producers. To attain the magnitude of production required to achieve this, a large investment is being made to develop new and rehabilitate existing key infrastructure at the Tonkolili Mine in Sierra Leone. The initial phase of infrastructure work constitutes the rehabilitation of the existing rail; clearing and grubbing dense vegetation; earthworks for a rail line; construction of bridges and the construction of a rail line. Stefanutti Stocks Civils have been awarded the construction of three composite bridges, which form a key role in the transportation of the iron ore from the mine to port. To a large extent local communities will be trained and employed to work on the construction project. The majority of plant, equipment and materials will be shipped in from South Africa and Europe. "Nature will present it's own challenges, including exposure to malaria, typhoid and yellow fever," says Shaun Butler, contracts director for Stefanutti Stocks Civils. "Rainfall, during May to October, can be up to 1.2m/month. It is therefore very likely we will be constructing causeways and platforms for the piling and civil construction in high flowing rivers." "We are preparing thoroughly for the challenges that lie ahead from a cultural, logistical and geographical aspect," said Shaun, "and are looking forward to bridging the expectations of our client." Site establishment on this project will commence in November 2010.

Colliery near Secunda

Source: Francois Vermeulen

In March this year Stefanutti Stocks Civils started construction on a 15 000ton coal bunker and 18km of overland conveyors for the Twistdraai Colliery Thubelisha Shaft Project. The scope of work includes earthworks, civil and structural steel work. Earthworks, due for completion in December 2010, include bulk and restricted earthworks as well as several retaining walls. The estimated volume of backfill is 40 000m3. Civil works, due for completion midFebruary 2011, include the construction of the 34m high and 150m long coal bunker, with an estimated concrete volume of 18 000m3. Large columns, up to 15m in height, are being placed in a single pour within a high turnaround cycle. Several take up towers and transfer towers are being constructed, as well as the railway crossings and overland concrete bridge. A total of 4 400 conveyor concrete sleepers will be constructed in-situ. Structural steel work, also due for completion mid-February 2011, includes the manufacture and installation of 14 chutes, with a total weight of 200ton. "Our timeline to complete the bunker is challenging," says Francois Vermeulen, contracts manager for Stefanutti Stocks Civils. "We have introduced a new formwork system comprising of floating tables for sloping walls and elevated slabs. It requires less staging and is saving us time as well as being a lot safer." The project employs 400 people at peak, and every possible measure and precaution was put in place to ensure compliance to all safety standards. A very successful safety campaign "Your Safety First" was introduced as a joint initiative between Sandvik, Tubular and Stefanutti Stocks Civils focusing on key areas of safety concern within the industry. "A total of 967 safety training courses have been attended, we have achieved 250 000 LTI free hours and the project has achieved a NOSA 5 Star award to date," states Francois. The project is due for completion in the first quarter of 2011. Quantities: · Earthworks: 40 000 m3 · Concrete: 21 000 m3 · Reinforcing: 2 100ton · Structural Steel: 200ton · Cast In Items (H/D Bolts): 25 000

PAGE 6 | Benchmark

Mining - Infrastructure

Khumani Iron Ore Mine - thickened tailings facility reduces

water wastage

Source: Ross Cooper

One of the operations teams at Khumani. thickeners, specialised pumps and high-pressure slurry pipelines, as well as the increased operating rate due to the additional flocculent and pumping costs. To reduce capital costs, it was decided that the operations would not follow the De Beers Central Treatment Plant (CTP) model (refer Benchmark Issue 1, May 2009, p16) which thickens the tailings stream to a maximum density, thereby requiring costly positive displacement pumps and a high pressure slurry pipeline. "The team decided the tailings would instead be thickened to a density that could still be pumped with centrifugal pumps," says Ross Cooper, contracts director, Stefanutti Stocks Mining Services. "To make this possible, the high rate thickener was located adjacent to and uphill of the deposition facility, approximately 11km from the plant." of 75% solids by mass). The free water is then returned to the plant by gravity. The set density and the fact that the high rate thickener is located uphill of the tailings facility means that the tailings stream can still be pumped using centrifugal pumps and that the slurry pipeline is rated at 40 bar (compared to CTP's 60 bar pipeline), resulting in a significant capital saving to the mine, whilst still recovering upwards of 80% of the process water pumped in the tailings stream to the facility. Due to the remoteness of the site, Stefanutti Stocks Mining Services are responsible for all ongoing operations at this tailings facility including operations of the thickeners, return of water to the plant, the slurry pump systems and the deposition facility.

Phase 1

In 2004 Stefanutti Stocks Mining Services (then known as ECMP) was awarded the contract to construct the entire tailings facility at the Khumani Mine, including the high rate thickener, pumping, pipelines, deposition facility and water dams. On completion of the feasibility study the project was awarded as a turnkey from detailed design through construction and operation. Processing ore consumes large amounts of water, with the majority of water loss occurring on the tailings facility of a mine. Sishen is a very dry area, and during the feasibility phase for the mine, client Assmang identified the need to reduce water losses as far was practical. In order to reduce the volume of water available for loss due to evaporation and seepage, it was accepted that the tailings would need to be thickened above conventional slurry densities to minimise the volume of water being deposited on the tailings facility. The downside of thickened tailings is the capital cost of equipment, including the high rate


To reduce the volume of slurry being pumped from the plant, a conventional large diameter thickener was provided at the plant to thicken the tailings to a relative density on the order of 1.3t/m3 (32% solids by mass). The underflow is then pumped to the remote high rate thickener where the density is increased further to approximately 1.8t/m3 (in excess of 62% solids by mass, compared to CTP being in excess

Phase 2

Based on the success of this methodology, Assmang awarded a second phase of the project to Stefanutti Stocks Mining Services in September 2009. This phase, currently underway, includes raising the deposition facility's outer embankment, construction of a second return water dam, construction of a second high rate thickener and installation of the required pumps and pipelines.

Tailings flow on deposition

PAGE 7 | Benchmark

Phase 1 High Rate Thickener

Deposition Point

Mining - Infrastructure

"This is a joint venture between Stefanutti Stocks Civils KZN and ourselves," says Peter Watt, contracts director for Stefanutti Stocks Civils. Approximately 300 people are employed at the site, this number will increase to around 500 people at the project's peak. There is a strong focus on recruiting local skills including labour, subcontractors and suppliers. The scope of work includes: · ROM bunker; · Discard bunker; · Conveyors and tunnel; · Screening building; · Cyclone plant; · Larcodems plant; · Three ROM feed silos; · Cyclone feed silo, product silo; and · Larcodems feed bin. "The two bunkers will be the largest coal bunkers within Southern Africa," says Peter. "They are 45 000ton and 40 000ton respectively and around 100 000m3 of concrete will be used between the two contracts." The project is due for completion at the end of 2011. The concrete batch plants and concrete boom placers were recently procured.

Expanding mining

infrastructure at Grootegeluk

Source: Peter Watt

Stefanutti Stocks Civils is back on site at the Grootegeluk coal mine in Lephalala, Limpopo where they are working on the Grootegeluk Medupi Expansion Project. In 2006 the company undertook construction of the Sintel Char Plant at Grootegeluk for client EXXARO Coal (Pty) Ltd. The expansion project comprises of two projects, which will run concurrently over an 18-month period and include the ROM and discard bunkers area civils, and the Plant civils.

View of the excavations at Grootegeluk.

DMO - upgrade of coal handling facility -


Portable water supply infrastructures for the DMO project comprising of 6 pump stations/sub stations.

new stackers

Source: Francois Vermeulen

As part of the Douglas-Middelburg Optimisation (DMO) the contract to construct linear and circular stackers, overland conveyors and water supply infrastructure plants was awarded to Stefanutti Stocks Civils in 2007 by client BHP Billiton (Bateman/Jones & Wagener/DRA). This project is scheduled for completion in November 2010 and entailed both earthworks and civils works. The bulk earthworks varied from drilling and blasting to depths of 12m as well as earthworks for several other structures and infrastructures at the mine.

Noteworthy Quantities: · Earthworks: 8 000m3 · Concrete: 14 000m3 · Reinforcing: 1 500ton

"At the projects peak we employed 355 people, which included 180 subcontractors," says Francois Vermeulen, contracts manager on the project. "During this three year, two month project all our people have undergone several training courses, including a constant refocusing on safety standards. The team must be congratulated on their compliance and attitude towards working safely." Stefanutti Stocks Civils received a safety award for their contribution to 2.5 million LTI free hours for the project.

Civil works included:

· · · Construction of 120m diameter circular stacker; Construction of a 700m linear stacker; Construction of several overland conveyors to total length of 14km with various intersections and cross overs; and

PAGE 8 | Benchmark

Mining - Infrastructure

pipeline and a potable water pipeline, as well as the construction of the platform for the new treatment plant.

ensuring that our client has a product which meets world class standards." Quantities: · Earthworks: 1 000 000m3. · 6km of HDPE pipelines laid. · Concrete: 1 200m3.

Optimum Water

Reclamation Plant

By Adrian Wellcome

Treatment of raw water is of utmost importance in today's day and age, where on a global scale societies are facing critical water shortages. To conserve and protect our planet for future generations, we need to think "GREEN". This was the motivation behind Optimum Coal Holdings initiating the Optimum Water Reclamation project at the Optimum Colliery in Pullenshope, Mpumalanga. Stefanutti Stocks Roads & Earthworks, working closely with Golder Associates Consulting Engineers, was the preferred contractor to execute this contract. The scope of works included the construction of a sludge and two brine ponds, including the implementation of the various pipelines that includes the raw water gravity feed pipeline, excess water

The aim of the new water treatment plant is to reclaim water used during mining operations. "There is a separation process whereby the water is pumped into newly built clarifiers after which the excess water is pumped through the excess water line and discharged into an open earth drainage system," explains Adrian Wellcome, site agent for Stefanutti Stocks. In conjunction with this process the clean water is pumped through to the existing Hendrina pump station, supplying fresh potable water to the neighbouring towns. During the separation process the solid waste will be discharged through a number of pipelines into the sludge and brine ponds. Due to design changes in the earthworks, coupled with numerous variation orders, the volume of earth that needed to be moved doubled and this had a significant effect on the contract duration. "Furthermore the excessive rainfall experienced during the current contract period has exceeded the average annual rainfall figures by 45%!" says Adrian. "This in turn had an adverse effect on the original completion date, nevertheless, our focus is to complete the current project successfully, thereby

Bulk earthworks for Styldrift

where possible, local subcontractors were used and materials procured from local suppliers when viable. "Stefanutti Stocks definitely made their mark in the community on this project," says Steve van der Walt, contracts director for Stefanutti Stocks Roads & Earthworks. "We donated a rock-fill parking area to the local police station, farming implements to the local community to start an AIDS feeding project, and were involved in an AIDS awareness drive whereby we donated 500 t-shirts to the community." The business unit also launched their safety awareness campaign at the Styldrift site in June 2010. In addition to tool box talks addressing various safety

topics, a banner displaying safety messages is displayed directly below the Incident Statistics Board. The site has thus far achieved 505 LTI Free Days.

mining platform

Source: Steve van der Walt

Stefanutti Stocks Roads & Earthworks commenced work at the Styldrift mine in November 2008. This project, consisting of bulk earthworks for a mining platform for client Bafokeng Rasimone Platinum Mine, will be complete at the end of 2010. The scope of works included 310 000m3 of bulk earthworks, an access road, a pollution control dam and conveyor road. Conventional blasting could not be undertaken as there were new houses in the area, thus chemical blasting was undertaken to alleviate any concerns from the local community. 90% of labour was sourced from the surrounding community. In addition,

PAGE 9 | Benchmark

Transport Nodes & Infrastructure

Overhauling one of Johannesburg's

major access bridges

By Axel Buhrman

Stefanutti Stocks Civils has completed a complete face-lift of Parktown's Saint Andrews Bridge - one of Johannesburg's busiest access bridges, which was widened to accommodate two additional new road lanes and pedestrian walkways, and new concrete barriers for additional safety. The internal and external structural system of the bridge was extensively strengthened and remodelled with its previous two edge beams on each side modified to create new stronger edge beams that would be able to take the required extra loading to the bridge deck. In addition to the logistical and technical complexities involved in working both on the surface and inside the bridge, the project had other key requirements: traffic on the busy M1 highway nine metres below the bridge itself was not to be disrupted, traffic disruptions over the bridge itself were to be minimised and it would have to continue to accommodate pedestrians. The aesthetic nature of the bridge also had to be considered and preserved, particularly in the form of the embedded blue mosaics on the bridge sides, which had to be safeguarded. "A complex project of this nature, while appearing very simple compared with major civil engineering projects, had to be a team effort to succeed," said Bruce Sparrow, site agent for Stefanutti Stocks Civils. "We had to work very closely with the design engineers, who came out quite often to monitor and sign-off for quality control purposes. Safety and quality were priorities. Our focus continually had to be on keeping our standards as high as possible." The eight-month project, which was completed by May 2010, required some 450m3 of concrete and 140tons of steel. For a detailed article on this bridge overhaul, please visit the news section at

Upgrading capacity at the

the second deck. The existing road will be re-graded to tie in with the level of the new bridge. The new bridge will ultimately comprise of a 101m long deck with spans of 37.75m over the north bound carriageway, 42.25m over the south bound carriageway and a 21m span at the eastern end. The deck will be constructed in two stages in the longitudinal direction and the twin decks will be joined by a 1m wide infill slab on the bridge centreline, cast after completion of all pre-stressing. The deck will be supported by simple bank seat type abutments with straight return earwing walls and the piers will be featured solid walls in form. The abutments and piers will each be founded on precast piles driven to estimated depths of ± 18m. As the new bridge will initially be constructed in two halves (transversely) it will be necessary to re establish for piling when the existing bridge has been demolished. "To shorten the programme the team proposed casting the 2m deep

Moss Kolnik Interchange

Source: Sheldon Randall

The Moss Kolnik interchange is located 25km south of Durban on the National Route 2 (N2). Significant traffic growth in the area resulted in capacity restraints on the existing interchange, warranting an upgrade, which was awarded to Stefanutti Stocks Civils KZN in January 2010. The scope of work includes the construction of a new six-lane bridge over the N2; the appropriate reconfiguration of the ramps on the east; and the widening of the existing ramps on the west. Once the first deck and ramps are completed, traffic will be re-directed onto these and the existing bridge across the N2 will be demolished to make way for

pre-stressed concrete box girders in one pour over the 101m," said Sheldon Randall, senior site agent for Stefanutti Stocks Civils KZN. "Permission was granted by the engineers on the basis that we cast the deck within seven days to prevent any differential shrinkage. The first pour took place on 20th September, the second pour on 27th of September." The first deck has been completed on programme, and preparation for diverting the traffic is underway before the demolition of the existing bridge takes place. The project is due for completion in October 2011.

PAGE 10 | Benchmark

Transport Nodes & Infrastructure

Lateral support for the entrances to the

Gautrain Station in Rosebank

Source: Eugene Kleynhans

Stefanutti Stocks Geotechnical was awarded the project at the Gautrain Station in Rosebank to excavate and support the entrance staircases and ventilation systems to the completed underground station. The entrances to the station consisted of two holes 60m long x 9m wide x 11.5m deep. Both entrances required contiguous piled walls with anchors and gunite arches to facilitate the support of the vertical excavation faces in the built-up environment. We started construction with the installation of forty-nine 600mm diameter reinforced piles on the perimeter of the excavations up to a depth of 15.5m. This was followed by the excavation of the first bench to a maximum depth of 3.5m. The first row of mechanical support, comprising of 300kN, 450kN and 600kN ground anchors were then installed followed by the application of gunite, mesh reinforcing and soil nails to retain the soil between the piles. This process was repeated three times to reach the required depth of 10.5m for the vertical excavations next to the existing roads and structures. The initial design had to be revised during construction to accommodate the neighbouring basements (found to be closer to the excavations than assumed in the original design) and the presence of unforeseen services. "The original project duration was 14 weeks," says site agent Eugene Kleynhans. "To the delight of our client, we completed the project two weeks ahead of schedule, notwithstanding the required changes to the design."

A strong

dolomitic drilling, investigative work and micro piles. · State-of-the-art electronic equipment, suitable for real time monitoring of ·

pile installation, all types of grouting and percussion drilling. Various grout mixers and shotcrete pumps, mostly utilised for slope stabilisation and grouting work.

geotechnical fleet

The Stefanutti Stocks geotechnical fleet includes: · Twelve crawler mounted hydraulic piling rigs ranging from 30 to 80ton, suitable for auger piles, cased piles and continuous flight auger piles. The sizes range up to 2.2m diameter and 38m deep. Ten percussion/rotary drill rigs ranging from 6 to 22ton for down the hole percussion and rotary drag-bit drilling, suitable for slope stabilisation work,


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Transport Nodes & Infrastructure

Reconstructing a

national road

Source: Ryan van der Walt

Stefanutti Stocks Roads & Earthworks is currently working on the reconstruction of an 87.4 km stretch of the N2 from Piet Retief to Camden Power Station. A new dual carriage way is being built on the first 7.5km stretch of the project and is being surfaced with 50mm asphalt and 13.2mm rolled in chips. From kilometer 7.5km to 83.3km the road is being rehabilitated by means of recycling, patching, slurry and a triple seal amounting to 550 000m2. The project is employing in the region of 170 people. Many of these stem from the local community and have undergone safety training and training to furnish them with skills required for their roles such as stop-go operators, flagmen and safety representatives.

Plant on site includes a 2m Wirtgen recycler, a 2m surface miller, three water carts, two graders and rollers. The paving crew constitutes a paver, a 14ton steel wheel drum and a PTR roller. "The logistics of working with and moving this bulky equipment requires a lot of attention and planning," says Ryan van der Walt, site agent on the project. "Our client, SANRAL, is very strict on process control and has a very stringent testing regime in place, in line with Colto." In order for Traffic to flow effectively on this national road the work is being staged in 5km work zones, Due to the rehabilitation being constructed in half width it is a requirement to institute stop go's manned, 24/7 . With the rainy season just starting, nature will present its own challenges.

The expected annual rainfall is between 700-800mm during the rainy season. The project commenced in September 2009, and to date 50% of the work is complete. The project is due for completion in September 2011.

Stefanutti Stocks adds Emulsion Plant to

prime, and the full spectrum of spray grades. "Our key objective, as a significant contributor to the South African road infrastructure, is to offer clients an alternative in the supply and manufacturing of quality road products," says Nick Dumond, site agent for the Roads & Earthworks division. "Our onsite laboratory will ensure that our products conform to all specifications, and our clients can be assured that their road binders are of the highest quality."

expand capabilities

Source: Nick Dumond

In 2009 Stefanutti Stocks Roads & Earthworks established an asphalt division in order to expand the business capacity to execute all types of road surfacing. This year, they have further expanded their in house capabilities by adding an emulsion plant to their comprehensive range of equipment. The unit has a ten ton per hour capacity, and has a multitude of product manufacturing capabilities covering the full emulsion range, anionic stable grade (SS60), cationic (fogspray, cationic spray) environmental friendly

PAGE 12 | Benchmark

PAGE 13 | Benchmark

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Power / Marine

Stefanutti Stocks Civils KZN was awarded the contract for the construction of the new Gingindlovu 132/88/22/11-kV substation for Eskom, on the outskirts of the small Zululand town of Gingindlovu. Work commenced in June 2010 with the removal of over 24 000m2 of sugarcane fields and bulk earthworks of over 20 000m3 by a subcontractor appointed by Stefanutti Stocks, who will also be constructing a new gravel access road as well as over 6 500m2 of landscaping. The substation is fenced off by over 500m of steel palisade fencing which was also subcontracted, to fencing specialists. We are also constructing the 100m2 control room with a 160m brick retaining wall splitting the substation down the centre. The concrete foundations in the yard range from just under 1m3 to over 7m3 and distributed across the 200 foundations are in excess of 1 000 holding down bolts. These range between 16mm to 36mm in diameter, each with a tolerance of 2mm. In addition to the numerous foundations there are three

new transformer bases complete with bund walls, an oil containment dam and underground piping system. "As we will also be installing the 3 500m copper earthmat, our site team has undergone intensive training and certification," says senior site agent, Bruce Ivins. The structural steel support work is split into contractor supplied and client supplied. Stefanutti Stocks Civils KZN has subcontracted out their portion of just over 200ton to a specialist structural steel manufacturer with extensive experience working on power related projects. "Clifford Msane, our site safety officer has been instrumental in the achievement of our first safety milestone of 25 000 man hours without incident," says Bruce. "The target for this project is 55 000 safe manhours, and we are committed to achieving this milestone." The contract is progressing well and is on programme and within budget.

Construction of the new Gingindlovu 132/88/22/11-kV


Source: Bruce Ivins

121 Tower steel foundations for

Reconstruction of Margate's famous

HydraPerseus 765kV

Source: Peter Ramaite

Stefanutti Stocks Power and Stefanutti Stocks Civils have been putting their muscle and energy into the HydraPerseus 765kV Project Section B in Petrusburg, where they are currently constructing 121 tower steel foundations. This is Stefanutti Stocks' first involvement in a 765kV Overhead Powerline project. Stringent SHEQ compliances required by Eskom as well as difficult excavations due to hard rock conditions resulted in lower production rates," says Peter Ramaite, projects manager for Stefanutti Stocks Power. "Contingency plans are already in place to ensure that the project key milestones set by the client are met by 30 October 2010." The division was asked to construct additional tower foundations for the main contractor on the project, in order to mitigate against late penalties which would be imposed. This was also successfully completed.

PAGE 15 | Benchmark

fishing pier

Source: Kevin Reid

After many years of neglect, the Margate Fishing Pier, once a hive of activity amongst local and visiting fishermen, is undergoing major structural reconstruction and rehabilitation. Pictured above: The team celebrates the achievement of a milestone. Back-row standing, from left to right: Herman Molebale, Guiseppe Lanzilotti, Martin Nel and Lazarus Setsepu. Sitting down, from left to right: Bonginkosi Manana, Bennet Motala and Joseph Radebe. Pictured below: Concrete casting operations at Tower 71, after it was inspected and approved for casting by the client. Stefanutti Stocks Civils KZN began with the reconstruction of the condemned pier decks and balustrades in June 2010, with the completion date set for early November 2010. "Working in this extremely temperamental environment with high tides and strong winds, has been a challenge on both safety and quality fronts," stated Anthony Graham-Jolly, site engineer for Stefanutti Stocks Civils KZN. "The team has, however, performed commendably to date, producing a good quality product."

Building Construction

Pictured is the Casagrande rig hard at work at Sandton City where Stefanutti Stocks Geotechnical undertook the lateral support earlier this year. This photograph, taken by Nick Partner, was placed second in the Stefanutti Stocks Structures photo competition.

Green Geotechnical engineering for

and will be the basement wall of the building," says Nell. The wall will require more than 1 000m3 of shotcrete. "A major challenge is that the bedrock was at a relatively shallow level - about three metres. Therefore the project required extensive blasting. This had to take place in a built up area and the presence of various existing services complicated matters even further. "In order to minimise the risk in the use of explosives, the proposed design of the blasting subcontractor was checked and approved by a third party and an independent party inspected the on-site

drilling and charging to conform with the design," says Nell. The explosive work was completed at the end of August without incident. "Another major challenge is transporting the excavated material from site as we have to take traffic patterns into account," says Nell. "This interactive contract requires us to work closely with our subcontractors. I believe our flexibility, strong team culture and modern equipment fleet gave us the edge when initially tendering for the project."

Menlyn Maine

By Wilhelm du Plessis (Construction World)

The long-awaited Menlyn Maine mixed-use precinct has broken ground with the construction of its first anchor tenant building for Nedbank, scheduled for completion late 2011 early 2012. Stefanutti Stocks Geotechnical was awarded the lateral support and bulk earthworks contract for this building. The development is envisioned to score highly in green standards, as the building systems are being designed and installed as per Nedbank's exact requirements. The documentation process for all building systems is being designed using Nedbank's experience in green building; the aim will be to achieve a 4-Star Design Rating. Thereafter, Menlyn Maine will submit for an As-Built certification. The green status of the building has implications for all that is part of the construction process. "In order for the project to remain green," says Tiaan Erasmus, commercial director of Stefanutti Stocks Geotechnical, "every aspect of everyone's subcontract had to adhere to strict green guidelines." "The scope of Stefanutti Stocks Geotechnical's lateral support and bulk earthworks contract is the excavation of a 13m deep hole which is roughly 80 x 80m (70 000m3 hole) and includes the various vertical supports of the walls of the excavated area as we proceed," explains Shaun Nell, managing director of Stefanutti Stocks Geotechnical. "It is a permanent wall, constructed with gunite

On site, from left to right: J Bitzer, Bishop Kgwete, Ernie van Tonder, Marius van der Merwe, Karel van Heerden and Dennis Ackerman.

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Building Construction

"The Wings of Knowledge".

An educational institution

fit for royalty

Source: Herman Smit

Stefanutti Stocks Building North West has been putting the finishing touches to a very unique, world-class educational facility in the North West Province. The Lebone II College, built in joint venture with JST, is situated in Phokeng and is an educational initiative of the Royal Bafokeng Administration - to promote and realise excellence in education for the Bafokeng people in the region and beyond. The college, which stretches over 515 hectares, consists of educational, recreational and residential facilities. The residential component for teachers and learners includes seven educators houses and two boarding houses, each accommodating 44 learners. The educational facilities, built over a period of 20 months by Stefanutti Stocks were designed as flexible learning environments where facilitators can encourage and foster creativity in thinking and learning - all 36 classrooms open out onto an enclosed courtyard space and lessons will be designed to explore both inside and outside spaces. The facilities also include Science and Biology labs, a school hall, music centre, theatre and an amphitheatre, tennis and basketball courts, as well as the dining area and kitchen.

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The sewage treatment plant was also constructed and a series of dams work in tandem with this sewage plant to be as ecologically friendly and self sufficient as possible. The water on the property is harvested for the irrigation of the school's playing fields. "This has been an incredibly exciting project to work on," says Herman Smit of Stefanutti Stocks Building NW. "The Wings of Knowledge provided us with an opportunity to put our skills to test - twelve 15m high columns had to be poured and set at 60 degrees in a V shape, within 20mm tolerance, off shutter concrete. The end result speaks for itself!" Where possible, materials were procured locally. The project created employment

for 230 people from the local community; 77 of whom received further training. The JST Stefanutti Stocks JV contributed to the botanical gardens, which are being developed on the premises.

Building Construction

The project team from left to right: Dichaba Ramotsho, Tony Bothma, Yolanda Biewenga, Giepie Barnard and Elias Phikane.

Constructing a conference centre

in Maun

Source: Giepie Barnard

In December 2009 Stefanutti Stocks Botswana returned to the remote town of Maun in Botswana, situated approximately 900km to the North-West of Gaborone. The company had constructed the impressive Maun Hospital in 2008, which included installing state-of-the-art technology to ensure the hospital could remain as self sufficient as possible should any of the services including electricity and air conditioning fail. Local hotel, Maun Lodge required a conference facility added on to their existing property, that would be independent from the existing hotel this meant a separate entrance, kitchen, dining room, bar, ablution facilities as well as an additional 26 bedrooms, three 135m2 conference rooms and parking for 70 vehicles. The contract started just before the rainy season, and had to be complete in time for a large SADC conference, starting 11 October 2010. Beneficial occupation was given to the furnishing/interior companies on 24 September 2010, and the hotel's new conference facility was up and running in time for the conference. "When working in remote locations, timing of everything is always critical," says Giepie Barnard, contracts director for Stefanutti Stocks Botswana. "In the case of this contract we got the vast majority of our supplies, including Stefanutti Stocks Housing, in a joint venture with S&B Construcoes Moc Lda, is currently on site in Tete Mozambique for client Vale Dos Embondeiros Lda. The project comprises of the construction of fifty houses for senior management and the associated infrastructure relating to sewer reticulation, a sewer treatment plant, complete water and electrical reticulation and the surrounding roads. We are currently busy with the installation of services, tiling, windows, skimming, ceilings, partitions and external plaster, with other finishes to follow shortly. "We are working at an intense pace to ensure the building will be sealed before the "Tete is very remote - 2 200km away from Johannesburg and about 1 800km from Maputo. The border crossing over the Zambezi River is a potential bottleneck," says Louis de Jager, managing director of Stefanutti Stocks Housing. "We are planning well ahead to ensure our material is delivered to site on time, in order for work to progress smoothly." Target completion date for the project is at the end of April 2011. rainy season hits us mid November," says Mathieu Carpenter, Stefanutti Stocks' site agent. "It's full steam ahead for all on site, as we push to achieve our targets, producing a quality product in the process." doors, window frames and panes from Cape Town and Johannesburg well before we required them. This was instrumental in the team completing this project in record time!"

Housing and Infrastructure in remote

Tete, Mozambiqe

Source: Louis de Jager

PWC Office Park on

Thabo Mbeki Drive, Lusaka

Source: Mathieu Carpenter

Stefanutti Stocks Building commenced work on the final phase of PWC Park accommodation project in Zambia in February 2010. The project comprises of the construction of the remaining two office blocks in the PWC Park development, a uniquely designed business park located on Thabo Mbeki Drive in Lusaka. Cavmont Bank Limited will occupy office blocks 3 & 4 once they are completed in December 2010.

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Building Construction

Wilgeheuwel Lifestyle Centre.

Brooklyn Mall, Gauteng.

Sandton Square, Gauteng. Randburg Waterfront, Gauteng.

Stefanutti Stocks

supports retail therapy

Source: Pieter Postema

Seaside Shopping Mall, Western Cape. Since the late 1970's, early eighties, when malls started becoming fashionable in South Africa, the Stefanutti Stocks Group has been involved in the construction of numerous shopping centres and retail complexes across the full spectrum of centre types. These include small shopping centres, suburban type shopping centres, large malls, themed shopping centres, retail facilities at tourist destinations and airports and centre refurbishments. Stefanutti Stocks subsidiary in the Middle East, interior fit out and refurbishment I'langa Mall.

Deira City Centre, Dubai, UAE. specialist, Al-Tayer Stocks, also have a list of impressive refurbishment and interior fit out projects in their portfolio, including Dubai Mall, Bloomingdales, Jumeirah Garden City and Deira City Centre. Centres that Stefanutti Stocks has constructed include Brooklyn Mall, the original Randburg Waterfront, Kollonade in Pretoria, La Lucia Mall Shopping Centre, uShaka Island Marine Park, Beacon Bay Crossing in East London, Wilgehewel Lifestyle Centre in Johannesburg, the new retail nodes La Lucia Mall, KZN.

Kollonade Shopping Centre, Gauteng. at OR Tambo, Cape Town International Airport, and the recently completed 105 000m2 I'langa Mall in Nelspruit. Stefanutti Stocks Geotechical has also been invovled at various shopping centres where they have provided lateral support and piling. Despite a slow down in the economy new retail developments or the refurbishment of existing shopping facilities around South Africa and neighbouring countries still seem to be very popular. Stefanutti Stocks Building is currently working on malls in South Africa, Botswana, Malawi and Mozambique. East Rand Mall, Gauteng.

Bloomingdales, Dubai, UAE.

PAGE 19 | Benchmark

Building Construction

Constructing the Gateway Mall

in Malawi

Source: Jean Kotze

Construction of the building work phase for the Gateway Mall in Malawi

was awarded to the Stefanutti Stocks Building business unit in early 2010 and the first members of the team from South Africa are currently in Lilongwe, busy with the site establishment. The Mall will be constructed in three sections: bulk earthworks, which are currently underway, and then the building works and civil works. The bulk earthworks are due for completion mid October 2010 after which Stefanutti Stocks will commence with their phase of constructing the 18 000m2 shopping centre. The project is due for

completion in the first quarter of 2012. "We aim to introduce best practices and procedures that have proven effective for us in Southern African countries, where the harsh conditions and access to materials and skills have required good logistical management," says Jean Kotze, contracts manager. "As this is our first project in Malawi, we want to make sure we make a lasting impression. There is big demand for civil and structural development in Malawi, which we certainly hope to contribute to in the future."

Revamping a shopping district BIFM house



in Gaborone

Source: Giepie Barnard

Once a shopping hub, the Main Mall in the heart of Gaborone suffered years of neglect and lost popularity as it began competing with newer and more glamorous malls. The city council began an initiative encouraging property owners to upgrade their buildings - part of this initiative was the revamp of BIFM House - a building upgrade awarded to Stefanutti Stocks Botswana. The complex renovation contract proceeded within a confined area, in the CBD, with only 3m space around the building to store materials whilst work was underway. Two old buildings were also going to be linked together to create a new 4 000m2 shopping space. Site establishment, storage and site offices were moved around within the areas that were not being used. Deliveries took place at night whilst there was no traffic in the mall, whilst any demolition work took place during the day so that the rubble could be removed at night. "We had to move tenants around to completed areas, before starting working on the newly vacated areas," says Giepie Barnard, contracts director on the project. "Our real challenges included ensuring constant ablution facilities were available, dust control, sound control, and of course security. Our site agent, Munyaradzi Chademana, was instrumental in ensuring we rose to the occasion, and the team must be congratulated on their success!" The project team, led by Construction Professionals, was extremely satisfied with the project, so much so that they negotiated a 50 000m2 shopping centre in Gaborone with Stefanutti Stocks. The Airport Junction project commenced mid October 2010.

Mares Shopping Centre and


Source: Ricardo G. Louro

The Mares Shopping Centre and apartments in Maputo Mozambique is made up of two phases. The first phase is a three floor, 19 000m2 shopping centre with 1 200m2 of office space and 6 000m2 of parking (supported deck). Phase 2 which commenced in July 2010 consists of six floors of luxury apartments (13 000m2) on top of the shopping centre. The target completion date for the shopping centre is November 2010, with the apartments completion a year later in December 2011. Construction of the shopping centre is taking place around an existing

supermarket, and logistics include managing the deliveries not only of our building materials but also of products and fresh produce for the supermarket. We have also had to demolish and construct new access for supermarket customers due to the building phases. "The fact that this is a fast track contract and we are working within a confined space means there is little margin for

error," says Ricardo Louro, contracts director. "We need to plan efficiently and effectively so as to cause as little disruption as possible both to the supermarket operations and to our work schedule." This is the second project S&B Construcoes (Moc) Lda. has undertaken for client Mario Gomes, a successful local businessman, who is also the project manager on this project.

PAGE 20 | Benchmark

Building Construction

place while we made a safe tunnel for tenant deliveries and the trading public." Internally every shop front in the mall was changed and the ceiling reconstructed at a higher level after lifting the existing services. Outside the centre, also without disrupting trade, the external walkways were demolished and larger ones reconstructed and covered by a new canopy. "The interface between the public, the trading tenants and the construction work face was a delicate balance of delivery, public perception and safety," says John. "The work faces were hoarded off to protect the tenants and public." On completion of the shopping centre a new building for Standard Bank was added onto the mall. The building shell with services was handed over in June 2010 for the bank to fit out internally. In acknowledgement of the exemplary safety standards on the project, the Hillside Mall received a 5-star Safety Award from Master Builders Association (more information on the MBA Safety Awards can be found on page 23 and 24). From left to right: Brandon Abdinor (executive director KZN MBA), John Dorning (contracts manager, Stefanutti Stocks Building KZN) and Francois Louw (president of the MBA KZN).

Hillside Mall, Bluff five stars for

safe shopping

Source: Hugo Burger and John Dorning

In the first of two projects for client Ndawanye Props 1002 cc. Stefanutti Stocks Building in KZN revamped the interior and exterior of the Hillside Mall in 2009, giving it a new and modern look in time for the Christmas trade. Safe and easy access for shoppers to all stores was a priority as the revamp took place around a live centre with only one entrance. "We had to construct a steel tower on a modified concrete structural support and clad the steel tower with Belau," says John Dorning, contracts manager on the project. "All this took

An extension to Bluff Towers

12 000m2 and 49 tenants were relocated to their new premises. During the first half of 2010 the team was back on site for client Old Mutual Property Group constructing an additional building to the shopping centre for tenant Mr. Price. The 653m2 two-storey building comprises of a basement, trade floor and roof parking and was built to merge with the existing Mr. Price store, which continued trading throughout construction. "The interface here was unique as the perimeter of the existing Mr. Price Home

shopping centre

Source: John Dorning

In 2005 Stefanutti Stocks Building refurbished the Bluff Towers shopping centre on Tara Road in the Bluff, Durban. Tenant capacity was increased by

had to be removed and extended onto the new footprint, " says John Dorning. A division wall was created to house Mr. Price Weekender, and to further challenge logistics and our site agent Hugo Burger, a new 200m2 line shop was constructed in the corner of the trading Mr. Price Home. The exemplary safety standards on this project were also acknowledged with a 5-star Safety Award from Master Builders Association (more information on the MBA Safety Awards can be found on page 23 and 24).

PAGE 21 | Benchmark


Roads & Earthworks -

awarded a NOSA 5 Star grading, recognising the significant endevours the business unit has put in place to maintain and implement systems that reduce risk in the work place. "Our support towards environmental sustainability is now becoming a focus, and we are incorporating Environmental Management into our Health & Safety System," states Pieter van den Berg, the business unit SHEQ manager. "The requirements warrant the development of specific standards which we are implementing. The effectiveness thereof will be audited by NOSA in the fourth quarter of 2010." manager at Stefanutti Stocks Roads and Earthworks. Hazards are identified then illustrated in a banner, with two cartoon characters role playing the safest practice in approaching these high risk activities. The banners and posters are being distributed to sites and the topics are discussed during toolbox talks. "We have ten topics for the year," says Francisco. "Our two launch topics of `Riding on Construction Vehicles' and `Hand Protection' were rolled out during June and July this year." acknowledged by NOSA with the award of a certificate of Special Recognition. S&B Group Swaziland followed suit when they achieved 1 million DI free hours in October 2010. "Management commends all our employees for their commitment, support and steadfastness in upholding health and safety as a high priority at our workplaces," says Pieter van den Berg of these significant safety results. third place in the Best Contracts Manager category; second in Best Site Safety Officer; third in R20m-R50m contracts category; second in R50m-R120m category; second in R120m-R200m category; and second and third places in the R200m-R500m category. Commenting on his company's exceptional achievement of attaining 5-star safety status on 11 sites, Greig Bastion, contracts director at Stefanutti Stocks Building Inland, said the geographical challenges in the quest for 5-star grading were overcome by ensuring that all the building sites not only presented compliant documentation but that site conditions reflected the company's SHEQ vision and employed best practices. "In this respect, our safety manager, Fanie Boucher, and newly-appointed safety administrator, Michelle Kok, played major roles," Bastion said. "With 5-star grading in sight, we have over the past year aimed to standardise safety systems across all provinces and encouraged inter-provincial competitiveness. Our site managers, too, have played an immeasurable role: seeking out and rectifying weaknesses they had never considered before." "Being recognised by the GMBA for our efforts has further inspired our commitment to establishing a strong culture of health and safety within all ranks of our company," states Bastion.

NOSA Five star grading

Source: Pieter van den Berg

The Stefanutti Stocks Roads & Earthworks Business Unit has been

Roads & Earthworks

Safety campaign

"In our drive to reduce incidents at the workplace, a safety awareness campaign was launched in June 2010, highlighting high risk activities associated with work our business unit undertakes," stated Francisco Santos, health and safety

Roads & Earthworks

1 and 2 million Dl free hours

On 23 May 2010 the Roads & Earthworks Business Unit achieved a milestone of 2 253 451 DI Free hours. This significant achievement was

GMBA honours exceptional health and

safety achievement

By Jan de Beer, GMBA

Stefanutti Stocks Building Inland were recently the recipients of a special award for achieving 5-star safety gradings on no fewer than 11 building sites simultaneously. The award from the Gauteng Master Builders Association (GMBA) was handed over at the annual Regional Health and Safety Awards and is the first such award to be made by GMBA. Stefanutti Stocks Building Inland, comprising of the regions of Gauteng and North West received several other awards from the GMBA this year including:

Greig Bastion (left) receiving the special award from Christian Robert, president of the GMBA.

PAGE 22 | Benchmark


FEM honours Stefanutti Stocks


FEM (Federated Employers Mutual) held its annual awards in Gauteng in September, where the management of Stefanutti Stocks Building KZN was presented with a platinum award - the first of its kind. Seeing as this award was the first of its kind, FEM consulted their record books going as far back as eight years to confirm the statistics and for the achievement of 1 000 000 manhours without a lost time injury, before making this prestigious award. In recognition of this outstanding achievement and the ongoing contribution by Stefanutti Stocks towards improving health and safety in KZN, Thelma Pugh, managing director of FEM will DOUBLE the rebate due to Stefanutti Stocks Building KZN for 2010.

FEM requested details regarding how they were able to achieve this with the intention of sharing their "secret" with other building contractors to point out to them what can be achieved with effort and management commitment. A long list of safety initiatives was submitted with emphasis placed on the following: · Safety is always the first item on the agenda at all management meetings and takes up about 30% of total meeting time. · Continuous training of all management staff. · Monthly safety meetings with site staff and sub-contractors. · Regular workshops held with all

· ·

· ·


safety officers. Monthly safety meetings held with Directors and Safety Managers. Getting the Department of Labour, FEM and Master Builders Association involved from project commencement to completion. Job specific training for all employees. Both Safety Managers are registered safety practitioners who are actively involved in Safety Institutes that are committed to reducing occupational accidents and injuries. All accidents and incidents are thoroughly investigated and special attention is given to reducing both the indirect and direct costs of accidents.

Stefanutti Stocks management, from left to right: Stephen Pell (COO), Dallas Pakkiri (health and safety manager); Howard Schwegmann (managing director) and Graham Carver (operations director). (Absent: Siven Naidoo, health and safety manager).

Master Builders Association honours

KZN safety achievements

At the Master Builders Association Awards Stefanutti Stocks in KZN was once again successful across all categories and were awarded the following:

1 2 3 4 5 6

Contract Stefanutti Stocks Building Ridgeside Offices Standard Bank - Bluff Mr Price - Bluff Souvaris Warehouse Unilever Warehouse Liberty Life project (combined)

Category R5m - R20m R5m - R20m R5m - R20m R20m - R50m R200m - R500m >R 500m

Award Regional 1st place, National 1st place Regional 2nd place Highly commended Highly commended Regional 1st place, National 2nd place Regional 1st place, National 1st place Best scaffold award, Best client award Best designer award Regional 3rd place Regional 1st place Regional 2nd place

1 2 3

Stefanutti Stocks Civils Northdene Formwork Yard RBM MSP Tailing Plant Moss Kolnick Bridge

Plant Yard Civils Civils

Building Business Unit

enjoys reduced DIFR

The Building business unit SHEQ committee meets four times a year to discuss and implement systems with the

2009 Nov 0.54 0.78 0.5 2 32 744,362 D.I.F.R - Actual D.I.F.R - Rolling D.I.F.R - Benchmark No of Incidents No of 12 month rolling DI's No of manhours Oct 0.31 0.77 0.5 1 35 639,977

aim of creating and maintaining a safe working environment for all concerned. The following points are stressed at each meeting: 1. Do not compromise safety for cost. 2. Management (directors) must lead by example. 3. Preventing accidents and incidents, thereby reducing the Business Unit DIFR 4. Adequate training of employees including management.

2010 May 0.00 0.44 0.4 0 18 824,779

5. Cross pollination of ideas. Looking at the steady reduction in the business unit DIFR over the last two years is testimony to the success of these meetings. In October 2009 our rolling DIFR was 0.77 and as at September 2010 we were able to reduce it to 0.27 which is currently below the Group benchmark of 0.4 (in September the DIFR for the Group was 0.29).

Dec 0.63 0.83 0.5 2 33 634,171

Jan 0.00 0.68 0.5 0 27 428,457

Feb 0.27 0.67 0.5 1 26 745,889

Mar 0.26 0.54 0.4 1 21 762,067

Apr 0.51 0.48 0.4 2 19 781,111

Jun 0.00 0.38 0.4 0 16 865,182

Jul 0.00 0.35 0.4 0 15 815,254

Aug 0.47 0.32 0.4 2 14 856,535

Sep 0.24 0.27 0.4 1 12 824,983

PAGE 23 | Benchmark

Safety / Development

KZN builds safety records with

1 million

manhours 1,5 million manhours at Liberty - free from

Stefanutti Stocks Building KZN recently achieved an incredible safety milestone of 1 000 000 manhours without a lost time injury. They have also, for the third year running, been awarded a 5-star rating by Master Builders Association KZN and are one of only two companies in KZN to achieve this. This incredible milestone bears witness to our company culture," says Howard

Schwegmann, managing director of Stefanutti Stocks Building KZN. "Safety is the first item on our agenda at company management meetings where we stress that safety is not to be compromised by cost. We recognise our responsibility for the health and safety of our employees, clients, contractors and the public alike, and our management takes this responsibility seriously always leading by example."

lost time injury

The R540 million Liberty Life project in Umhlanga, has achieved 1 500 000 manhours without a lost time injury. This includes hours worked by all subcontractors and spans the two-year period, since the project commenced

in 2008. The construction team on this project has won numerous awards in both regional and national MBA safety competitions, including:

Safety Achievements Year 2008 2009 2009 2010 2010 2010 Contract Phase 1 Phase 1 Phase 2 Phase 3 Phase 1,2,3 Liberty Life Project Value R120m - R200m R120m - R200m R200m - R500m R50m - R120m Over R500m Combined Value R540m Awards Achieved 5 Star Rating, Regional 1st Place National 1st Place, Presidential Award > 95% Regional 2nd Place Achieved 5 Star Rating, Reginal 1st Place, National 1st Place Achieved 5 Star Rating Regional 1st Place (Awaiting National Auditing) Achieved 1 million manhours (March) Achieved 1.5 million manhours (May)

1,5 million man-hours

Stefanutti Stocks Civils -

5-star NOSA award

"We achieved the 5-star NOSA award in 2009, and were determined to maintain

it in 2010," says Gustav Nel, safety manager for Stefanutti Stocks Civils. "We obtained a higher overall score this year, and now have our eye on the sought after NOSCAR award. Our employees are committed and responsible for conducting their activities in a manner which ensures both their safety and that of the people around them. Our management lead by example, and we are looking forward to a 5-star safety record going forward."

Arming the

community with skills

Source: Danie Basson

In October 2009 Stefanutti Stocks Roads & Earthworks, together with TSK Projects, launched a Road Construction Learnership outreach in Bethal, where they are working on the N17 upgrade between Bethal and Davel. There are 15 individuals (seven females, eight males) participating in this learnership programme where members of the community will qualify in a National Certificate in Road Construction NQF Level 2 over a one-year period. "The short term objective is to equip the

participants with construction, building and maintenance skills for our company projects and other related business skills needed on such projects, " said Danie Basson, HR manager for Stefanutti Stocks Roads & Earthworks. In terms of the long term benefits to the participants, this on site classroom based training equips participants with skills that will increase their employability, once

Stefanutti Stocks completes the project and leaves the area. The learners were assessed by a TSK Projects' senior assessor, who was very impressed with their progress and dedication. The success of this development initiative is made possible by the support and encouragement that site management and staff is lending the programme.

Pictured below: The 15 learners currently enrolled on the National Certificate in Road Construction NQF Level 2.

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Socio Economic Development

Structures Business Unit supports

individuals to find effective solutions to whatever challenges they may face. The schools that Kohin is involved with consist of 86.5% of children from a previously disadvantaged backgrounds. "Kohin's work with approximately 100 000 youths in communities across South Africa is translating into a healthier, more stable younger generation,"

said Schalk Ackerman, managing director of the Stefanutti Stocks Structures Business unit. To date 100 full-time youth coaches have been placed in schools around the country, a number the organisation is hoping to increase through sustainable support of full-time Kohin youth coaches.

youth coaches

Source: Anton Stroebel

The Stefanutti Stocks Structures business unit recently donated R94 000 to Kohin, a South African organisation that seeks to empower the youth of South Africa with hope, vision for the future and answers to the unique challenges they face daily. Kohin trains and equips aptly suited youth coaches with the skills to assess the many different factors that influence young people's lives, and to guide these

Left to right Schalk Ackerman, managing director, Structures Business Unit; Fanie Bolleurs, chairman, board of directors, Kohin; Anton Stroebel, human resources manager, Structures Business Unit.

After-School Programme to develop

maths and science skills

Source: Anton Stroebel

In line with their commitment to investing in the skills of the youth of South Africa, Stefanutti Stocks Civils has contributed R75 000 to the Mamelodi After-School Programme. This is an initiative of the University of Pretoria based at their Mamelodi campus.

The programme was established in response to challenges concerning the national mathematics and science results. The objective is to resolve the cause of low academic results by tackling both learner and teacher skills. The programme has set specific and measurable targets, including increasing the maths and science results of 170 Grade 12 learners, providing these learners with the necessary learning aids and setting up practical teaching opportunities for ten student-teachers from the University of Pretoria. "We have supported this initiative in previous years," says Werner Jerling, managing director of Stefanutti Stocks pre-primary to Grade 12, living with a wide variety of physical disabilities, ranging from Cerebral Palsy to visual impairment. As a non-profit organisation the school relies heavily on fundraising, school fees and the support of donors to be able to provide learners with a good education, in a pleasant and conducive learning environment. "We have supported the Open-Air School in the past and have seen their good work and results with the children," said Nick Pousson, Stefanutti Stocks' director. "We look forward to future endeavours and opportunities where we can once again support the school."

Civils. "This community enrichment programme is proving very successful with the pilot project in 2008 showing an average improvement of 15% in learners results."

Werner Jerling, managing director of Stefanutti Stocks Civils hands over a cheque for R75 000 to Edwin T. Smith, director of the Mamelodi campus, University of Pretoria.

Building KZN donates

R20 000 to Open-Air School

Source: Nadine Gieseler

In September 2010 Stefanutti Stocks Building KZN donated R20 000 to the Open-Air School, which is to be put towards the school's electronic wheelchair fund. The school caters for approximately 260 learners from

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Nick Pousson handing over the cheque to the Open-Air pupils. From left Nicole Padayachee, Nick Pousson, Claude Pillai and Lwazi Gumbi.

Socio Economic Development / Social

Youth in construction

week - KZN

Source: Nadine Gieseler

Stefanutti Stocks Civils KZN and Stefanutti Stocks Building KZN participated at this year's Youth in Construction Week, held in the KZN province for the second year running. "We saw a marked increase in both attendance and interest in technical fields by the learners visiting the event and our stand this year," said Nadine Gieseler, human resources manager for Stefanutti Stocks in KZN. The regional organisers of the event are working closely with the education department, familiarising the educators

with the construction industry requirements to ensure better guidance for students and their subject choices in the future. "Our intention is to continue to participate in this and other events that encourage entrance into our industry," commented Nadine.

Stefanutti Stocks Building in the North West Province donated a football kit to the up and coming Tsokwane Football Club. From left to right are: Kobus Koekemoer (contracts manager Tau Pride); Kealeboga Sega (chairman Tsokwane Stars FC); Reginald Phetlhu (administrator Tsokwane Stars FC); and Almation Nkoana (HR manager Stefanutti Stocks Building Inland).

SAICE bridge building


Source: Nadine Gieseler

Stefanutti Stocks Civils KZN sponsored both the SAICE Durban and the SAICE Pietermaritzburg Bridge Building competitions this year. The competition in Durban has been going for 20 years, and has successfully promoted science and technology to high school students in a fun and

entertaining way. The Stefanutti Stocks exhibition stand drew many students and teachers alike, creating awareness of our company's capabilities as well as promoting the civil engineering profession to aspirant scholars intending to pursue a career in engineering. "It is most interesting to see the resourceful and innovative bridge designs produced by these budding young engineers," comments John Jackson, managing director of Stefanutti Stocks Civils KZN. "There is little doubt that both annual bridge building competitions have, since their inception, captured the imagination of learners and teachers who continue returning for more every year".

Stefanutti Stocks KZN

Golf day 2010

Source: Jeshika Singh

The Stefanutti Stocks Building KZN and Stefanutti Stocks Civils KZN golf day has become an increasingly popular event with many of our clients and consultants, and this year was no different! Held on 23 September 2010 at the Royal Durban, our annual golf day was well attended by clients, consultants and staff, some who travelled from Johannesburg, Cape Town & Richards Bay, especially to participate in this event. The day provided an opportunity to thank our clients and consultants for their support over the past year, and created a platform to network with key role players in the industry. With many prizes to be won, the game soon progressed from a social to a competitive event. The winning 4-ball was well rewarded with digital photo

frames and even the "most golfer" was recognised for his efforts (or lack thereof...).

Women's Day in


Source: Nadine Gieseler

Stefanutti Stocks in KZN marked this year's Women's Day by inviting a guest motivational speaker, Roma Howard, to speak on creating balance in life, prioritising and goal setting - in personal and work environments. "Women's Day provided the ideal opportunity to make our ladies feel special, help them to identify their key roles in their personal lives as well as the work place and to give recognition to the value they bring to their functions in the work place," said Nadine Gieseler, human resource manager at Stefanutti Stocks in KZN. The ladies were also treated to goodie bags and a delicious lunch.

The winning 4-ball. From left to right, Eugene Cox (Barloworld Jhb), Wikus du Plessis (Stefanutti Stocks Building KZN); Ian Hayes-Hill (Edgecombe Hayes-Hill) and Andrew Setzkorn (Schoombie Hartman).

"Most golfer" (in other words the worst golfer) is Mr Grahame Carver.

PAGE 26 | Benchmark


Families from Stefanutti Stocks Mining Services.

Family Day at

Stefanutti Stocks

Saturday 16 October was family day for the Stefanutti Stocks business units in Gauteng. The majority of the province's colleagues and their families spent the day at Fountains Valley, Pretoria, where good food, camaraderie, recreation and entertainment were the order of the day.

Stefanutti Stocks Structures Business Unit

Stefanutti Stocks'

Photo competition

This year's competition was won by Bruce Ivins for his photograph of the KSIA Interchange Bridge in KwaZulu Natal. This bridge was a landmark World Cup project constructed by Stefanutti Stocks Civils KZN. The opening of the new King Shaka International Airport on 1 May 2010 was very dependent on the completion of the bridges and the interchange. The construction of the bridge, (completed in May 2010), was featured on National Geographic in June, in a programme called "Build up to the Cup - Train". Second prize, went to Nick Partner for his photograph taken at Sandton City. This photograph is featured on page 16. The photograph of the St. Andrews bridge in Parktown, taken by Bruce Sparrow, was awarded third prize. The three winning photographs will feature in the Stefanutti Stocks 2011 calendar. First.

football heroes

Source: Almation Nkoana

9 October 2010 was another memorable day for the Group's football loving employees who came from a variety of sites to participate in the Group Annual Soccer Tournament, at Esselen Park School of Excellence. 16 teams took part in this prestigious Group soccer trophy. The winning team, for the fourth year running, was the Roads and Earthworks Plant team (pictured with their trophy below).


Stephen Pell, Group COO, hands the trophy to captain of the winning team, Nigel Ramiah.

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