Sika’s technologically advanced construction products were top of mind when
Eskom initiated a project valued at R31billion for construction of the new coalfired
Kusile Power Station. Planning started in 2007 for the new power station
situated on a 5200-hectare site, 40km outside Witbank, Mpumalanga. The
primary amount was allocated for the boiler and turbine contract, while a
further R2.9billion was earmarked in 2008 for the main civil engineering
contract. Sika’s Gauteng Technical Sales Consultant, Jacobus Pretorius had
the responsibility of ensuring Sika’s supplies were on site on time.

While construction commenced in April 2008, the Kusile Power Station will
only be completed in approximately eight years, and already numerous ranges
and quantities of Sika’s world-renowned products have been instrumental in
this project. After Medupi Power Station in Limpopo, Kusile, which means “it
has dawned’ in the Nguni language, will be Eskom’s second most advanced
coal-fired power plant. Consisting of six units, each rated at approximately
800MegaWatts-installed capacity; Kusile Power Station will generate a total
of 4800MegaWatts, making it the second largest coal-fired power station in
the world. Anglo Coal South Africa has committed to supplying 17 million tons
of coal over a period of 47 years. The first unit is planned for commercial
operation in 2014, while the remaining units will be commissioned in
approximately eight-month intervals with the last unit expected to be commercially operative by 2018.

This major contract was awarded to Stefanutti Stocks, Group 5, Basil Read
and WBHO Construction who joined forces to form Kusile Civil Works Joint
Venture. The collective JV unequivocally specified a vast range of Sika’s versatile
and innovative products. Phase 1 of the project involved construction of the
power station buildings, administration buildings, a high voltage yard and
roads.
No less than seven Sika products have been used for waterproofing various
structures: SikaTop Seal-107 ZA; Sikalastic-150, and the products in the
Sikalastic-600 series. Sikagard-720 EpoCem has been applied on the vertical
and horizontal concrete surfaces of the structures. The Sikalastic-800 series
of products has been used to provide anti-corrosive coatings. Sika’s MonoTop
series of polymer-modified mortar products is playing a vital role for concrete
repairs on the project. Further products used in this category are Sika Rep
and Sika Rep LW. SikaTop Armatec 110 EpoCem is providing excellent adhesion
and a high degree of mechanical strength. SikaGrout-212 and Sikadur-42 LE
are two products used for grouting.

Structural repairs are being made using the Sika Anchorfix range, and Sika’s
internationally renowned CarboDur Plates are playing a vital role in securing
the validation of the structure. A number of Sika’s flooring products have been
supplied to ensure the power station’s horizontal surfaces meet stringent
specifications: Sikafloor-261 ZA (SS2), Sikafloor-20N and -21N PurCem.

During clearance of this huge site, Eskom has ensured that strict conservation
measures have been implemented; high integrity wetlands and two heritage
sites have been preserved, graves have been relocated and indigenous trees
and plants have been replanted elsewhere. To date, more than 6million m³ of topsoil has been relocated to be used for rehabilitation and leveling of the
site once construction is complete.

When the first unit of Kusile Power Station is officially opened in 2014, Eskom
will be secure in the knowledge that Sika has played an integral part in its
construction, and as this multi-billion Rand project grows, Sika will continue
supplying its world-renowned, state of the art products for many years to
come.